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Dulcodes LP with Comfort ControllerUV system

Assembly and operating instructions

A2244

EN

Original Operating Instructions (2006/42/EC)983668 Version: BA DS 055 07/17 EN

Please carefully read these operating instructions before use. · Do not discard.The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the maleform in grammatical structures but with an implied neutral sense. Itis aimed equally at both men and women. We kindly ask femalereaders for their understanding in this simplification of the text.

Please read the supplementary information in its entirety.

Information

This provides important information relating to thecorrect operation of the unit or is intended to makeyour work easier.

Warning informationWarning information includes detailed descriptions of the haz‐ardous situation, see Ä Chapter 2.1 „Labelling of Warning Informa‐tion“ on page 7.The following symbols are used to highlight instructions, links, lists,results and other elements in this document:

More symbols

Symbol Description

Action, step by step.

⇨ Outcome of an action.

Links to elements or sections of these instructions or other applicable documents.

n List without set order.

[Button] Display element (e.g. indicators).Operating element (e.g. button, switch).

„Display /GUI“ Screen elements (e.g. buttons, assignment of function keys).

CODE Presentation of software elements and/or texts.

General non-discriminatory approach

Supplementary information

Supplemental directives

2

Table of contents1 About this UV System........................................................... 6

1.1 Correct and Proper Use ............................................... 62 Safety.................................................................................... 7

2.1 Labelling of Warning Information.................................. 72.2 Users' qualifications...................................................... 82.3 Dulcodes safety information......................................... 92.4 Safety equipment........................................................ 102.5 Information in the Event of an Emergency ................. 10

3 Storage, transport and ambient conditions......................... 113.1 Permissible ambient conditions.................................. 113.2 Packaging material..................................................... 11

4 Function.............................................................................. 124.1 Commissioning........................................................... 124.2 Normal mode.............................................................. 134.3 Automatic wiper (optional).......................................... 134.4 Temperature monitoring............................................. 134.5 Switching off............................................................... 13

5 Operation and Control (Comfort Control)............................ 145.1 Control elements......................................................... 145.2 Data Backup and Menu navigation............................. 165.3 The main menus and the sub-menus......................... 185.4 Adjustable parameters / access code......................... 205.5 Access code............................................................... 225.6 Setpoints 1 or 2........................................................... 235.7 Start wiper cycle......................................................... 245.8 Operating data............................................................ 245.8.1 Read error list.......................................................... 245.8.2 Read lamp data....................................................... 245.8.3 Read sensor data.................................................... 245.8.4 Read log book entries.............................................. 255.8.5 Measured values..................................................... 255.8.6 Control Values 1 or 2............................................... 255.8.7 Events...................................................................... 255.8.8 Operator actions...................................................... 255.8.9 Read information..................................................... 255.8.10 Write information.................................................... 255.9 Service........................................................................ 255.9.1 Calibration factor...................................................... 255.9.2 Delete lamp data...................................................... 265.9.3 Delete sensor data................................................... 265.9.4 Permit emergency mode.......................................... 275.9.5 Initialising the EEPROM (restoring factory settings) 275.10 Commissioning......................................................... 275.10.1 Language............................................................... 275.10.2 User code ............................................................. 275.10.3 Display unit (Physical unit)..................................... 275.10.4 Transfer pump control............................................ 285.10.5 Behaviour in the event of a fault ........................... 285.10.6 Minimum radiation intensity................................... 29

Table of contents

3

5.10.7 Operating times..................................................... 305.10.8 Control................................................................... 325.10.9 Analogue output XA1............................................. 335.10.10 Analogue input XE2............................................. 335.10.11 Analogue input XE3............................................. 335.10.12 Temperature input XE4........................................ 335.10.13 Minimum mains voltage....................................... 345.10.14 Other inputs and outputs..................................... 34

6 Assembly and Installation................................................... 356.1 Reactor....................................................................... 356.1.1 Assembly................................................................. 356.1.2 Attaching the Warning Sign and Nameplate to the

Reactor.................................................................... 356.1.3 Hydraulic Connections............................................. 366.2 Control Cabinet and Control....................................... 366.2.1 Assembly................................................................. 366.2.2 Electrical connections.............................................. 376.2.3 Fitting the temperature sensor................................. 376.2.4 Assembly and connection of the limit switch........... 376.2.5 Connecting the UV Sensor...................................... 386.3 Fitting the UV Lamp Protection Tube.......................... 386.3.1 Fitting the UV lamp protection tube without the

wiper........................................................................ 386.3.2 Fitting the UV Lamp Protection Tube with Auto‐

matic Wiper.............................................................. 386.4 Assembly and connection of the UV lamps................ 396.5 Assembly and installation of the wiper motor

(optional)..................................................................... 407 Commissioning................................................................... 41

7.1 Check the control system programming..................... 417.2 Leak testing and ventilation of the reactor.................. 427.3 Switching on the UV System...................................... 427.4 Adjustable functions and parameters......................... 42

8 Maintenance....................................................................... 448.1 General Information.................................................... 448.2 Cleaning with a Wiper................................................. 458.3 Cleaning with Cleaning Solution by Filling the UV

System........................................................................ 458.4 Cleaning the UV lamp protection tube and replacing

the wiper element....................................................... 468.5 Dismantling and Cleaning the UV Lamp Protection

Tube and Sensor........................................................ 478.6 Maintaining the wearing parts of the automatic wiper. 518.6.1 Tools........................................................................ 518.6.2 Replace these wearing parts after 1000 wiper

cycles, earlier if necessary....................................... 528.6.3 Instructions: Replacing the wearing parts ............... 528.7 Replacing the lamp..................................................... 718.8 Calibrating the UV sensor........................................... 73

9 Troubleshooting (Faults and Warnings).............................. 749.1 Warning messages..................................................... 759.2 Fault messages.......................................................... 77

Table of contents

4

10 Technical Data.................................................................... 7910.1 Setting Data.............................................................. 7910.2 Control Cabinet......................................................... 80

11 Dimensional drawing........................................................... 8211.1 Dimensional drawing Dulcodes LP 1x230W ...

6x350W..................................................................... 8211.2 Dimensional drawing Dulcodes LP 1 ... 4x350W

with automatic wiper................................................. 8312 Appendix............................................................................. 84

12.1 Spare parts, UV system, without wiper..................... 8412.1.1 Spare parts, 230 W, single lamp system without

wiper...................................................................... 8412.1.2 Spare parts, 1x350 W, single lamp system without

wiper...................................................................... 8512.1.3 Spare parts, 2x350 W, UV two lamp system

without wiper.......................................................... 8612.1.4 Spare parts, 3x230 W, three lamp system without

wiper...................................................................... 8712.1.5 Spare parts, 3x350 W, three lamp system without

wiper...................................................................... 8812.1.6 Spare parts, 4x350 W, UV four lamp system

without wiper.......................................................... 8912.1.7 Spare parts, 6x350 W, six lamp system without

wiper...................................................................... 9012.2 Spare parts, single lamp system with wiper.............. 9112.2.1 Spare parts diagram, single lamp system with

wiper...................................................................... 9112.2.2 Spare parts list, 3x350 W, single lamp system with

wiper...................................................................... 9412.3 Spare parts, 2 ... 4x350 W, multiple lamp system

with wiper.................................................................. 9612.3.1 Spare part diagram, 2 ... 4x350 W, multiple lamp

system with wiper.................................................. 9612.3.2 Spare parts list, 2x350 W, two lamp system with

wiper...................................................................... 9912.3.3 Spare parts list, 3x350 W, three lamp system with

wiper.................................................................... 10112.3.4 Spare parts list, 4x350 W, four lamp system with

wiper.................................................................... 10312.4 Dulcodes UV system operating log......................... 105

13 Declaration of Conformity................................................. 10614 Index................................................................................. 108

Table of contents

5

1 About this UV SystemDulcodes UV systems are used for the disinfection of:n Potable watern Process waterThe water to be disinfected is subjected to short-wave UV radiationduring the UV disinfection process. This so-called UV radiation killsany germs quickly and reliably.The UV system can also be used for breaking down combinedchlorine in swimming pool water.Dulcodes UV systems are supplied ready for connection. The UVsystems are available in different designs, defined by their identitycode. The performance data can be found in the data sheetenclosed with the Dulcodes UV system.Scope of deliveryn Reactorn Lamp with lamp protection tuben UV-C sensorn Pt 1000 temperature sensorn Control cabinet with controln DocumentationDepending on the system type, the UV system either has no wiperor is equipped with an automatic wiper.

n Automatic wipern LAN/WLAN communication interface

1.1 Correct and Proper Use

Correct and Proper UseThe operator is liable for damage caused by instal‐lation and operating errors!– The system is intended solely for the treatment

of water.– The system may only be used in accordance

with the technical data and specifications out‐lined in the operating instructions!

– Any other use or modification of the system isprohibited.

– The system may only be operated by trainedand authorised personnel!

– It is imperative that the information in the oper‐ating instructions relating to the differentphases of the unit's service life is observed!

Application

Available options:

About this UV System

6

2 Safety2.1 Labelling of Warning Information

These operating instructions provide information on the technicaldata and functions of the product. These operating instructions pro‐vide detailed warning information and are provided as clear step-by-step instructions.The warning information and notes are categorised according tothe following scheme. A number of different symbols are used todenote different situations. The symbols shown here serve only asexamples.

DANGER!Nature and source of the dangerConsequence: Fatal or very serious injuries.Measure to be taken to avoid this danger.Description of hazard– Denotes an immediate threatening danger. If

the situation is disregarded, it will result in fatalor very serious injuries.

WARNING!Nature and source of the dangerPossible consequence: Fatal or very serious inju‐ries.Measure to be taken to avoid this danger.– Denotes a possibly hazardous situation. If the

situation is disregarded, it could result in fatalor very serious injuries.

CAUTION!Nature and source of the dangerPossible consequence: Slight or minor injuries.Material damage.Measure to be taken to avoid this danger.– Denotes a possibly hazardous situation. If the

situation is disregarded, it could result in slightor minor injuries. May also be used as awarning about material damage.

NOTICE!Nature and source of the dangerDamage to the product or its surroundings.Measure to be taken to avoid this danger.– Denotes a possibly damaging situation. If the

situation is disregarded, the product or anobject in its vicinity could be damaged.

Introduction

Safety

7

Type of informationHints on use and additional information.Source of the information. Additional measures.– Denotes hints on use and other useful informa‐

tion. It does not indicate a hazardous or dam‐aging situation.

2.2 Users' qualifications

WARNING!Danger of injury with inadequately qualified per‐sonnel!The operator of the plant / device is responsible forensuring that the qualifications are fulfilled.If inadequately qualified personnel work on the unitor loiter in the hazard zone of the unit, this couldresult in dangers that could cause serious injuriesand material damage.– All work on the unit should therefore only be

conducted by qualified personnel.– Unqualified personnel should be kept away

from the hazard zone

Training Definition

Instructed personnel An instructed person is deemed to be a person who has been instructed and,if required, trained in the tasks assigned to him/her and possible dangers thatcould result from improper behaviour, as well as having been instructed in therequired protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructedperson and who has also received additional training specific to the systemfrom ProMinent or another authorised distribution partner.

Trained qualified per‐sonnel

A qualified employee is deemed to be a person who is able to assess thetasks assigned to him and recognize possible hazards based on his/hertraining, knowledge and experience, as well as knowledge of pertinent regula‐tions. The assessment of a person's technical training can also be based onseveral years of work in the relevant field.

Electrician Electricians are deemed to be people, who are able to complete work on elec‐trical systems and recognize and avoid possible hazards independently basedon his/her technical training and experience, as well as knowledge of pertinentstandards and regulations.Electricians should be specifically trained for the working environment inwhich the are employed and know the relevant standards and regulations.Electricians must comply with the provisions of the applicable statutory direc‐tives on accident prevention.

Customer Service depart‐ment

Customer Service department refers to service technicians, who havereceived proven training and have been authorised by ProMinent to work onthe system.

Safety

8

Note for the system operatorThe pertinent accident prevention regulations, aswell as all other generally acknowledged safetyregulations, must be adhered to!

2.3 Dulcodes safety information

WARNING!UV-C radiationPossible consequence: Serious injuries.UV-C radiation is harmful to the eyes and skin– Only operate the UV lamp UV-C when it is fully

fitted and installed.– Install the UV lamp in the UV system in accord‐

ance with the regulations prior to commis‐sioning.

WARNING!Live parts!Possible consequence: Fatal or very serious inju‐ries.– Measure: Disconnect the device from the

power supply before opening it.– Disconnect damaged and defective devices or

devices that have been tampered with from thepower supply.

WARNING!Insufficient water treatmentPossible consequence: Illness.Please read the technical data sheet for your UVsystem.Ensure that:– The maximum permissible water flow rate is

not exceeded.– The UV transmission does not fall below the

permissible level.– As otherwise adequate treatment of the

water cannot be guaranteed.

WARNING!Falling objectsPossible consequence: Crushing of feet.Remedy: Wear safety shoes.

Safety

9

CAUTION!Overheating of the lamp and reactorPossible consequence: Material damage.– Only switch on the UV system after the reactor

has been filled with water.

CAUTION!Unauthorised operating parametersPossible consequence: Material damageEnsure that:– The installation place is dry and frost-free.– There is guaranteed protection for the UV

system from chemicals, dyes and vapours.– The ambient temperature and the radiation

temperature in the direct vicinity of the systemdo not exceed 40 °C.

– The maximum permissible operating pressureis not exceeded.

– There are no solid particles and no turbidity inthe water to be treated.

– If necessary, fit an appropriate treatmentsystem upstream of the UV system.

2.4 Safety equipmentATTENTION: Hazardous ultraviolet radiation

UV-C UV-C radiation is harmful to the eyes and skin! The UV lampsmay only be operated when installed. The UV system should beinstalled in accordance with all pertinent regulations prior to com‐missioning the UV lamps.ATTENTION: Hazard

Disconnect the system from the mains power supply or switchoff the master switch prior to commencing maintenance work.Depressurise the reactor prior to commencing maintenance work.

Disconnect the system from the mains power supply or switchoff the master switch prior to opening.

2.5 Information in the Event of an EmergencyIn the event of an emergency, switch the red-yellow main switch onthe side of the control cabinet to OFF or disconnect from the mainspower supply.

Labels on reactor

Labels on control cabinet

Safety

10

3 Storage, transport and ambient conditions3.1 Permissible ambient conditions

Permissible ambient temperature: - 20 °C ... + 70 °C.Humidity: maximum 95 % relative air humidity, non-condensing.Other: No dust, no direct sunlight.

Permissible ambient temperature: + 5 °C ... + 40 °C.Humidity: maximum 92 % relative air humidity, non-condensing.Other ambient conditions: No dust, no direct sunlight. No corrosivegases, vapours and dust.

3.2 Packaging material

Packaging materialDispose of packaging material in an environmen‐tally responsible way. All packaging componentscarry the corresponding recycling code .

The packaging is intended to protect the components from damagebefore installation. Do not damage the packaging and only removejust before installation.

During storage

During operation

Storage, transport and ambient conditions

11

4 Function

Shut-off valves and flushing valves do not formpart of the scope of deliveryThe shut-off valves and flushing valves do not formpart of the scope of delivery of the UV system andare provided by the operator on site.

The water to be treated flows through the stainless steel reactorpast the UV lamp. The UV radiation disinfects the water.

A0917

1

23

4 5 6

7

Fig. 1: Typical installation diagram for a UV system1 Shut-off valve (supplied on site)2 Flushing valve (supplied on site)3 Sampling taps (supplied on site), fireproof4 Shut-off valve (supplied on site)

5 Reactor6 UV sensor7 Control

The low-pressure UV lamp generates a very high output of UVradiation, which is particularly effective for the treatment of water.The UV lamp is located in a lamp protection tube made of high-grade quartz with a high level of UV transparency.The compact design of the reactor and the flow result in evenly dis‐tributed radiation of the entire stream of water.A control monitors the UV system together with the UV sensor.

4.1 CommissioningOnce the Dulcodes UV system has been switched on, the UVlamps are ignited. Following ignition, the UV lamps need severalminutes until the UV lamps reach operating temperature.The UV sensor monitors the UV lamps. As soon as the UV outputhas exceeded the minimum radiation intensity threshold, the rinsevalve opens for the start rinse.If the minimum radiation intensity is not exceeded within the max‐imum permissible warm-up time, then the rinse valve will openregardless. However, if the minimum radiation intensity is also notexceeded within the maximum rinse duration, then the controlswitches the UV system off and goes into fault mode.The shut-off valve is opened after the start rinse is completed. TheUV system goes into normal mode.

Operation of the UV system in „Control“ operating mode: Toensure the fault-free control of the UV lamps, control of the UVlamps starts 5 minutes after the UV system has started.

Function

12

4.2 Normal modeIn normal mode, the UV sensor continues to monitor the UVoutput:If the UV output falls below the warning threshold: A warning isoutput.If the UV output falls below the minimum radiation intensitythreshold: The shut-off valve closes and the rinse valve opens.However, If the minimum radiation intensity threshold is also notexceeded within the maximum rinse duration, then the controlswitches the UV-system off and goes into fault mode.All UV lamps are monitored to ensure that they operate optimally. Ifa UV lamp fails, the shut-off valve is closed and the controlswitches the UV-system off and goes into fault mode.

4.3 Automatic wiper (optional)

During the wiper process, the warning thresholdand the minimum radiation intensity threshold arenot monitored; consequently the shadowingcaused by the wiper does not trigger a false alarm.

If you press the Enter key in the „Wiper“ display, then a wipingprocess is triggered. This is independent of whether the UV systemis „ON“ or „OFF“ .If you start the wiping process in warm-up mode, the warming upprocess is stopped and once the wiping process is ended, thewarm-up time is restarted.

After elapse of the set interval time, an automatic wiper cyclestarts. This function cannot be deactivated.In the event of a wiper fault, the UV system issues a warning mes‐sage, but the UV system remains in operation.

4.4 Temperature monitoringThe water temperature in the reactor is monitored continuouslywhile the UV lamp is in operation.As soon as the water temperature exceeds the maximum tempera‐ture, the UV system goes into fault mode.

4.5 Switching offWhen the UV system is switched off, the shut-off valve closes andthe UV lamps are turned off. If the UV lamps require postburning,then the lamps are switched off after the lamp postburning durationhas elapsed.

Manually triggering a wiper cycle

Regular wiping

Function

13

5 Operation and Control (Comfort Control)5.1 Control elements

A2030

1.

2.3.

4.5.6.7.

8.9.

10.

Fig. 2: HMI control elements1 LCD display2 [i] key / jump to value and move to right3 [UP] key4 [DOWN] key5 [START/STOP] key6 [OK] key; jump to the menu.7 [ESC] key8 Operating indicator (green)9 Warning indicator (yellow)10 Fault indicator (red)

Control elements

Operation and Control (Comfort Control)

14

A2115

Operation: 2 h

Normal mode

116 W/m2

Fig. 3: Continuous display: Normal mode. Display in W/m2 or J//m2

LED and symbols Function

Red LED The system is in fault mode.

Yellow LED The system has warning messages.

Green LED The system is in operation.

The SD card is in its socket and is active.

⇨ or ⇦ The flashing arrow symbol means that the wiper is operating andindicates the direction of movement.

offon

Fault

Lamp start sequence

Lamp operation status

1. Lamp pre-warming 2. Lamp start (<1 s) 3. Lamp operation

Lamps off. Electronic ballast not connectedto supply voltage.

Lamps off. Electronic ballast in standby.

Lamps on. Normal mode.

Lamps off Electronic ballast was switched off because of a fault.

Lamps off. Current undervoltage or excessive temperature.

offon

Fault

offon

Fault

offon

Fault

offon

Fault

offon

Fault

offon

Fault

offon

Fault

RedGreenYellow

RedGreenYellow

RedGreenYellow

RedGreenYellow

RedGreenYellow

RedGreenYellow

RedGreenYellow

RedGreenYellow

A2467

Fig. 4: Operating status and LED displays of lamp operation equipment.

Continuous display

LED indicators and symbols


15

5.2 Data Backup and Menu navigation

Data backup / limited service lifeThere is a possibility of loss of data with all types ofdata storage. Data loss can be caused by damageto hardware, software, or unauthorised access etc.The operator of the device is responsible forbacking up data recorded by the data logger. Thishas to be done in accordance with the national andinternational requirements, regulations and stand‐ards applicable to the operator of the device.Define and document this data backup in a backupor recovery plan.The manufacturer of the device is not responsiblefor backup or recovery of data.SD cards only have a limited service life. Thisservice life is based, for example, on the generalageing of the SD card and due to the memory type(Flash Memory) from the fundamentally limitednumber of write processes. Bear this in mind withyour data backup strategy and ensure that youregularly use your SD card.

The maximum size of the SD card is currently 512 MB.The SD card is currently supplied as an industrial 512 MB SD card.Unlike „consumer“ cards, industrial SD cards have an operatingtemperature of up to 85°C and the data is stored twice in the SDcard's memory for security reasons.

SD card


16

A2257

Operation:

Normal mode

Main menuAccess codeSetpoint

Operating dataService

Main menuSetpoint

Operating dataServiceCommissioning







Access code

Language: German

Display unit

Commissioning

Setpoint

100%

Read error listRead lamp data

Operating data

Read log book entriesRead information

Read sensor data

Various text messages.Press ESC key to go back.Additional submenus available.

Calibration factorDelete lamp data

Service

Initialise EEPROM

Delete sensor data

User codeVarious text messages.Press ESC key to go back.Additional submenus available.

~ 2 seconds

Operating times

Analogue output XA1Analogue input XE2Analogue input XE3Temperature input XE4

Write information

User codeExpert codeUser code

User code 5000

Transfer pump control

Permit emergency mode No

Off



Wiper cycle

Start wiper cycleYes

No

Start wiper cycle

Start wiper cycle

Start wiper cycle

Start wiper cycle

Start wiper cycle

Behaviour in the event of a fault

Control

Fig. 5: Main menus and sub-menus of the user interface.


17

5.3 The main menus and the sub-menus1st level 2nd level 3rd level 4th level 5th level

Mainmenu

Access code User code

Expert code

Setpoint 1 or 2 0 ... 100%or

0 ... max. value m3/h

Start wiper cycle No/Yes

Operating data Read error list Error number with texts

Read lamp data Lamp number with texts

Read sensor data UV sensor with texts

Read log book entries Measured values Measured values withtexts

Controller values Controller values withtexts

Events Events with texts

Operator actions Operator actions withtexts

Read information Software versions IO type UVCb-LPIO ware01.00.00.00HMI type UVCb-LPHMI ware00.02.06.04HMI data01.00.00.00EEP datan02.03.00.02

Hardware versions IO board01.00.00.00HMI 01.08.00.00

Current identity codeUVCb*****

Write information Yes/NoAll setting data is written to the SD card.

Service Calibration factor 1,000

Delete lamp data

Delete sensor data

Permit emergencymode

Initialise EEPROM

Commissioning Language German


18

1st level 2nd level 3rd level 4th level 5th level

User code 5000

Display unit(Physical variable)

W/m2 / J/m2

Transfer pump control Yes/No

Operating times Maximum rinsing time

Start rinse time

Maximum free rinsetime

Lamp post-burn time

Wiper interval

Date

Time

Measured valuerecording

Control Controller operatingmode

No control

Manual flow

External flow

Controller values 1 Setpoint 1

Transmission

Target dose

Delay period of thresh‐olds

Delay period ofthresholds

Analogue output XA1 Current signal: 4 ... 20mA

Max. radiation intensity100 W/m2

Analogue input XE2 Function OFF

Flow

Analogue input XE3 Function

Current signal

Max. turbidity

Temperature input XE4 Function OFF

Temperature


19

5.4 Adjustable parameters / access codeAdjustable parameters / access code

Description Startingvalue

Increment Minimumvalue

Maximumvalue

Access code Access con‐dition

Main menu

Access code 5000 1 1 9999 --- ---

Setpoint 1 or 2 100% 1 % 43 % 120 % User code ---

Setpoint 1 or 2 20 m3/h 0.1 m3/h 0 m3/h 999.9 m3/h User code ---

Wiper cycle No No --- ---

Yes

Operating data --- ---

Service level 1

Calibration factor 1 0.001 0.001 9.999 Expert code System On

Delete lamp data Expert code System Off

Delete sensordata

Expert code System Off

Emergency modepermitted

No No Expert code System Off

Yes

InitialiseEEPROM

No No Expert code System Off

Yes

Commissioning level 1

Language German German User code None

English

French

Spanish

Italian

User code 5000 1 1 9999 User code System Off

Display unit W/m2 W/m2/ User code System Off

J/m2

Transfer pumpcontrol

Off Off Expert code System Off

On

Operating times level 2

Maximum rinsingtime

5 min 1 min 1 min 99 min Expert code System Off

Commissioningof rinsing time


Maximum freerinse time


Lamp post-burntime


Wiper interval 2 h 1 h 1 h 100 h Expert code System Off


20



Maximumvalue


Date 01.08.2015 01.01.2014 31.12.2100 User code System Off

Time 12:00 00:00 23:59 User code System Off

Measured valuerecording

60 sec 1 sec 1 sec 600 sec Expert code System Off

Control level 2

Controller oper‐ating mode

Controllervalues 1

Controllervalues 1


Delay periodof thresh‐olds

Control values 1level 3

Setpoint 1 100% 1 % 50 % 100% User code System Off

Minimum radia‐tion intensity

50.0 W/m2 0.1 W/m2 0.0 W/m2 Warningthreshold 1


Warningthreshold

50.0 W/m2 0.1 W/m2 Minimumradiationintensity

999.9 W/m2 Expert code System Off

Transmission 98 % 1 % 75 % 98 % Expert code System Off

Target dose 400 J/m2 1 J/m2 300 J/m2 3000 J/m2 Expert code System Off

Max. flow System-specific

0.1 m3/h System-specific

System-specific


Delay periodthresholds level 3

0 seconds 1 second 0 seconds 1800 sec‐onds


Analogue output XA1 level 2

Current signal 4 mA 0 ... 20mA Expert code None

4 ... 20 mA

Max. radiationintensity

100.0 W/m2 0.1 W/m2 0.1 W/m2 999.9 W/m2 Expert code None

Analogue input XE2 level 2

XE2 functionalmode

off off Expert code System Off

Flow

XE2 currentsignal

4 mA 0 ... 20mA Expert code System Off

4 ... 20 mA

Maximum flowvalue

System-specific

0.1 m3/h 0.1 m3/h 999.9 m3/h Expert code System Off

Analogue input XE3 level 2

XE3 functionalmode


Turbidity

Combinedchlorine


21



Maximumvalue


XE3 currentsignal

4 mA 0 ... 20mA Expert code System Off

4 ... 20 mA

Max. turbidity 1.00 NTU 0.01 NTU 0.01 NTU 10.00 NTU Expert code System Off

Max. combinedchlorine

1.00 ppm 0.01 ppm 0.01 ppm 20.00 ppm Expert code System Off

Temperature input XE4 level 2 System Off

XE4 functionalmode


Tempera‐ture

Maximum oper‐ating temperature

50 °C 1 °C 0 °C Max. watertemperatureless 5 °C


5.5 Access code

„Access code“ displayUnder the main menu option „Access code“ youenter the known access code. This access codecan be the user code or the expert code.Once the correct access code has been entered,preferences can be set in the service, commis‐sioning, or configuration menus. Once entered, theaccess code remains for up to 5 minutes afterleaving the settings menu.

You can input the user code or the expert code in the „Accesscode“ main menu item. You have differently extensive rights,depending on which of these access codes you have input. Youcan use the table Ä Table on page 22 to see which code ismatched with a given adjustment option. The access code (user orexpert) must be entered in the menu item „Access code“ prior toany actions undertaken by the operator. If you have input anaccess code that is too low to be able to change a certain param‐eter, you can select the parameter, but cannot change this param‐eter.

Name Enables ... Access code

User code Enables functions that users mustapply in their day-to-day work.

Factory setting: 5050Adjustable in the menu:„Commissioning“ > „User code“

Expert code Enables additional functions thattechnical experts must use intheir day-to-day work.

Is only disclosed during technical experttraining courses or on request as systeminformation.


22

5.6 Setpoints 1 or 2

Warning messages and system faultsTo avoid warning messages and system faults, thelamp output should be set so that the sensor signalat the set lamp output is clearly above the warningthreshold.

The control can automatically switch between 2 setpoints via a dig‐ital contact input. Only setpoint 1 is activated in the factory setting.Setpoint 2 can be activated by the service technician, if required,during commissioning. Please contact the manufacturer’s Servicedepartment for subsequent activation.

In „No control“ operating mode, the lamp output can be set withina range of 50 ... 100 % of the nominal electrical power of the lamp.If during operation, the output of the UV lamp falls and the sensorsignal reaches or falls below the warning threshold, the lampoutput should be changed accordingly.

Control of the lamp outputThe lamp output is only controlled within a rangespecified by the electric ballast (50 ... 100%).

You can specify the setpoint in „Manual flow“ operating mode.During operation, the lamp output is then controlled so that thespecified sensor signal is adhered to. Consequently, there is auto‐matic adjustment of the UV system to changing operating condi‐tions, such as lamp ageing, variations in water quality etc.After inputting the controller values:n Setpoint (maximum flow),n Transmission,n Target dose,the control then calculates from this the associated minimum radia‐tion intensity (sensor signal), target radiation intensity and the con‐trol variable for the lamp output.

Adjusting the lamp output in controloperating mode „No control“

Adjusting the setpoint in „Manualflow“ operating mode


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Control of the lamp outputThe lamp output is only controlled within a rangespecified by the electric ballast.

You can adjust the lamp output via the analogue signal of anexternal flow meter in „External flow“ operating mode.The control calculates the associated minimum radiation intensity(sensor signal), target radiation intensity and the control variablefor the lamp output from the value:n Flow signal,n Transmission,n Target dose.The prerequisite for the use of the „External flow“ function is theconnection of a flow meter (4 ... 20 mA) to the analogue input XE2.There is automatic adjustment of the UV system to changingparameters, such as:n Fluctuating flow,n Lamp ageing,n Fluctuating water quality,n etc.

5.7 Start wiper cycleThe „Start wiper cycle“ menu item is available if your UV systemhas an automatic wiper. If an additional cleaning requirementexists, you can trigger a wiper cycle additional to those at the pro‐grammed interval by pressing the key. The warning and minimumradiation threshold are not monitored during the wiper process. Ifthe wiper cycle is not completed within a specified period, awarning is issued. The UV system continues to run; however, nofurther wiper cycles are triggered.

5.8 Operating data5.8.1 Read error list

The current faults and warnings are displayed along with the faultnumbers.

5.8.2 Read lamp dataInformation relating to the electronic ballast and connected UVlamps is displayed.

5.8.3 Read sensor dataInformation relating to the UV sensor is displayed.

Adjusting the setpoint in „Externalflow“ operating mode


24

5.8.4 Read log book entriesAll events, operator actions, controller values and measured valuesare displayed. Number 1 is the most recent entry. As the numbersincrease, the entries get older.

5.8.5 Measured valuesThe recorded measured values for the minimum radiation intensityand, if connected, the measured values for both analogue inputsXE2 and XE3 are displayed.

5.8.6 Control Values 1 or 2The control values set are displayed for:n Transmission in %n Target dosen Setpoint 1 or 2 (Maximum flow)

5.8.7 EventsThe last events will be displayed.

5.8.8 Operator actionsThe last operator actions carried out are displayed.

5.8.9 Read informationThe software and hardware information, and also identity code, aredisplayed.

5.8.10 Write informationThe adjustment data is written to the SD card in a text file"Report.txt".

5.9 ServiceYou can only make changes to the service menu with the correctaccess code. Every change is entered into the log book with thedate and time.

5.9.1 Calibration factorThe UV sensor is factory-calibrated and does not require any fur‐ther adjustment. The minimum radiation intensity must be set cor‐rectly to maintain effective disinfection.

The following applies to non-certifiedsystems:


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WARNING!Poor disinfectionCause: Defective calibration of the UV sensor.Consequence: Defective water disinfection.Measure: The UV sensor must be checked regu‐larly using a reference radiometer. The UV sensormust be replaced at least every 2 years or after10,000 operating hours, depending on whichoccurs first, by a UV sensor with a valid calibrationcertificate.

WARNING!UV radiationCause: If the UV sensor is removed, UV radiationthat is harmful to the eyes and skin UV-C will beemitted from the sensor window when the UVlamps are switched on.Consequence: Possible irreversible damage to theskin and eyes.Measure: Operating the UV system with the UVsensor removed is therefore only permissible whenchecking and recalibrating the UV sensor. Wearthe designated protective gear when checking andcalibrating the UV sensor e. g. protective goggles.

Always check the UV sensor at least twice a year. However, withflow rates over 100 m3/h, check it once a month using a referenceradiometer. A certified reference radiometer with a valid calibrationcertificate is required for checking the UV sensor.In the event of an unauthorised deviation between the referencemeasurement and UV sensor, the measured value of the UVsensor must be adjusted using the calibration factor so that themeasured value agrees with the reference measurement. Inaccordance with worksheet DVGW W 294, the calibration factormay only be set within the range of 0.8 ... 1.2. In the event that thedeviation between the UV sensor and reference radiometer is sogreat that the UV sensor display value can no longer be harmon‐ised, the UV sensor must be replaced with a UV sensor with a validcalibration certificate. On this subject, see the specifications inDVGW worksheet W 294.

5.9.2 Delete lamp dataAfter the lamp has been changed, the operating hours and thenumber of lamp changeovers can be set to "0" individually for eachUV lamp. The total operating hours of the UV system are notaffected.You can reset the lamp data only in the „Off“ state.

5.9.3 Delete sensor dataYou can set the operating hours to "0".The UV sensor data can only be reset in the „Off“ state.

The following applies to certified sys‐tems:


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5.9.4 Permit emergency mode

Non-certified systemsThis function is only available for non-certified sys‐tems.

The „Emergency mode“ function is enabled in order to keep theUV system running with limited output in the event of a fault, e. g. alamp failure in a multiple lamp system. In order to activate thisfunction, you must also activate emergency mode in the commis‐sioning menu.

5.9.5 Initialising the EEPROM (restoring factory settings)If you initialise the EEPROM , then all setting data is reset to itsdefault value:n All setting datan All configuration datan All lamp operating hours and lamp changeoversn All sensor operating hoursn The operating time of the system

5.10 CommissioningAdjustments can only be made in the commissioning menu oncethe correct access code has been entered in "Access code" in themain menu.

5.10.1 LanguageYou can select between different languages. You can also changethe language in the „Off“ state.

5.10.2 User codeThe system control has a user code for protection against unau‐thorised modifications of the system control settings. This usercode enables the programming mode for users/operators. You canfreely select the user code. The programming mode remains disa‐bled after a change of the user code. The lock is only cancelledwhen you have input the new user code under [Access code].

5.10.3 Display unit (Physical unit)The UV sensor monitors the UV output and the disinfection effi‐ciency. The unit of measure of the sensor signal display (radiationintensity) is W/m².The UV dose of the UV system is calculated depending on the:n UV transmission,n Flow,n Radiation intensity.


27

The control calculates the UV dose displayed from these values.The UV dose can be displayed on the HMI by converting the unitdisplayed to J/m2.

5.10.4 Transfer pump control

CAUTION!Damage to the UV lamps and reactorCause: The UV system may only be operatedwhen the reactor is fully filled with water. With anempty or only partially filled reactor there is a riskof damaging the UV lamps.Measure: It must be ensured that the reactorcannot run empty when the transfer pump isswitched off. As the transfer pump has a certainpost-rinse duration, the lamp postburning timeshould be set to at least one minute. This ensuresthat water conveyed during the post-rinse period isdisinfected.

The pump control system must be activated in order to control thefeed pump with the pump relay. The pump relay releases when theUV system is switched off and remains released with „pumpcontrol off“ , even when the UV system is running.If the UV system is switched on with „pump control on“ then theUV system will exit warm-up mode only when the warningthreshold is exceeded. The pump relay operates.If the UV system is switched off or the UV system switches over topause mode, the pump relay will release.If the minimum radiation intensity is not reached during operationor a UV lamp fails, then the pump relay will release and the UVsystem switches to fault mode.

5.10.5 Behaviour in the event of a fault

CAUTION!Reduced disinfection efficiency in emergencymodeEmergency mode is not permissible for applica‐tions where high demands are made of the disin‐fection performance, such as e. g. drinking waterdisinfection.Emergency mode is not available for certified sys‐tems.In emergency mode, any shut-off valve that maybe available opens immediately, and not after theminimum radiation intensity has been exceeded.The minimum radiation intensity is not monitored. -The UV system operator must check prior to ena‐bling emergency mode in the programming menu,and also any time before emergency is switchedon, that there is no risk to personnel or property asa result of the significantly reduced UV intensity.


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Operator's ResponsibilityResponsibility for the use of emergency mode lieswith the UV system operator, with all its conse‐quences.

Normally the UV system is switched off in the event of a fault. How‐ever, for certain applications it can be a good idea to continueoperating the UV system with a reduced output. This operatingstatus is called emergency operation.If emergency mode has been selected when a fault has occurred,the UV system switches to fault mode in the event of lamp failureor if the minimum radiation intensity is not reached, after comple‐tion of the rinse free duration. If the OK button is pressed in theevent of a fault, the system switches to emergency mode.Emergency mode can also be activated by shutting the "Emer‐gency mode" switch input.Bridging the "Emergency mode" switch input causes an automaticswitchover to emergency mode.

5.10.6 Minimum radiation intensity

WARNING!Poor disinfectionCause: Insufficient radiation intensity in UVsystem.Consequence: Poor disinfection performance ofthe UV system.Measure: The minimum radiation intensity isdependent on the type of system and the max‐imum flow through the UV system, which can betaken from the enclosed data sheet for the UVsystem.

NOTICE!The minimum radiation intensity must be below thewarning threshold. It is not possible to set it abovethe warning threshold.

The system issues a warning should the UV output drop so far thatthe sensor signal falls below the warning threshold.To prevent it from dropping below the warning threshold, the UVlamp protection tubes should be cleaned, the UV lamps replacedor the water quality improved by means of appropriate water treat‐ment.Dropping below the warning threshold is signalled on the display (1downward arrow). A signal device can be connected to the signalrelay of the control. The relay is closed when the signal falls belowthe warning threshold.

Warning threshold not reached


29

Reliable and safe water treatment can no longer be guaranteed ifthe UV output falls so low that the UV sensor signal drops belowthe minimum radiation intensity threshold. In this case, a shut-offvalve, should one be fitted, will close and a rinsing process is initi‐ated.To prevent the value from falling below the minimum radiationintensity, the UV lamp protection tubes should be cleaned, the UVlamps replaced or the water quality improved by means of appro‐priate water treatment.If the minimum radiation intensity is not reached, this is indicatedon the display (2 downward arrows). If the sensor signal remainsbelow the minimum radiation intensity after the rinsing process, theUV system switches off and goes into fault mode. A signal devicecan be connected to the signal relay of the control. The relay isclosed when the signal falls below the minimum radiation intensity.

5.10.6.1 Minimum radiation intensityThe minimum radiation intensity depends on the UV system typeand the maximum flow through the UV system. The minimum radi‐ation intensity values can be found in the technical data sheet ofthe UV system.

The minimum radiation intensity is calculated from the flow enteredor from the external flow signal.

5.10.6.2 Warning thresholdThe warning threshold depends on the UV system type and themaximum flow through the UV system. The minimum radiationintensity values can be found in the technical data sheet or on thenameplate on the UV system. When entering the setpoint, refer tochapter .Set the warning threshold 5 ... 10% above the minimum radiationintensity.

The warning threshold is calculated from the flow entered or fromthe external flow signal.The warning threshold is 5% above the minimum radiation inten‐sity.

5.10.7 Operating times5.10.7.1 Maximum rinsing time

The maximum permissible water temperature in the reactor ismonitored. In the event of excessive temperature, the UV systemautomatically activates the rinsing process. If the maximum permis‐sible water temperature does not fall by approx. 5 °C within themaximum permissible rinsing time, the control switches off the UVlamp and enters fault mode.

Minimum radiation intensity notreached

„No control“ operating mode:

„Manual or external flow“ operatingmode:

UV systems in operating mode „Nocontrol“ :

UV systems in operating mode„Control on“ :


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5.10.7.2 Start rinse time

In most cases, a start rinse time of "1 min" is suffi‐cient.If there is no rinse valve available, the start rinsetime can be set to "0 min".

The start rinse time is intended to ensure that only optimallytreated water can flow through to the consumer. As soon as the UVlamps reach operating temperature after ignition and the UVsensor signal has exceeded the minimum radiation intensity, theautomatic rinse valve opens (if fitted) for the start rinse process.Only then does the shut-off valve open.

5.10.7.3 Maximum time rinse freeThe free rinsing process is primarily used for the disinfection ofdrinking water. Free rinse times of > 10 hours are often usedduring drinking water disinfection. After periods of heavy rainfall itis possible that UV transmission will decrease e. g. if the water haspoor natural filtering characteristics. The sensor signal then fails toreach the minimum radiation intensity.During free rinsing the shut-off valve closes and the rinse valveopens. Once the water quality has improved, the UV systemswitches back to normal mode. However, if the sensor signal failsto exceed the minimum radiation intensity within the maximumrinse free time, then the UV system switches to fault mode.

5.10.7.4 Lamp post-burn timeIn large-scale UV systems, it may take some time for the shut-offvalve to close in some cases, or for the water flow to be stopped byanother means. In the case of drinking water disinfection, the lamppost-burn prevents insufficiently disinfected water from reachingthe consumer while the UV system is being shut down. In mostcases, a lamp postburning time of 1 minute is sufficient.

5.10.7.5 Wiper intervalHere you can adjust the pause between two wiping processes. Youcan only change the wiper interval in the „Off“ state. This menu isonly present if a wiper device is present.

5.10.7.6 Setting the dateYou can only change the date in the „Off“ state. The European dis‐play format is used.

5.10.7.7 Set timeYou can only change the time in the „Off“ state. The European dis‐play format is used.


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5.10.7.8 Measured value recordingYou can adjust the time intervals in which the measured values areentered into the log book.

5.10.8 ControlYou can set the controller operating modes here.

5.10.8.1 No controlTo save energy, the lamp output can be reduced with new UVlamps, and with UV systems operating with a flow rate lower thanthe maximum permissible flow. There is no control in this operatingmode.The lamp power can be adjusted manually between 50 ... 100% ofthe nominal electrical power. If during operation, the output of theUV lamp falls and the sensor signal reaches or falls below thewarning threshold, the lamp power should be increased incremen‐tally up to the maximum permissible value. The minimum radiationintensity and warning threshold must be set manually.

5.10.8.2 Manual controlIn „Manual control“ operating mode, specify the setpoint of thesensor signal by inputting the values:n Flow,n UV transmission,n Target dose.The control calculates the required radiation intensity (sensorsignal) from the input values. Consequently, there is automaticcontrol of the UV system to changing operating conditions, such aslamp ageing, variations in water quality etc.

5.10.8.3 Flow ControlIn „Flow control“ operating mode, the lamp output is additionallydetermined by the external command variable of a 0/4 ... 20 mAsignal from a flow meter. The following values also need to beentered:n UV transmission,n Target dose.The control calculates the required radiation intensity (sensorsignal) from the values entered and the current flow signal. Conse‐quently, there is automatic control of the UV system to changingoperating conditions, such as lamp ageing, variations in waterquality etc.

5.10.8.4 Control combined chlorineFunctions in similar way to the "Flow control" operating mode, butthe external command variable is provided by the concentration ofcombined chlorine.


32

5.10.9 Analogue output XA1The signal from the UV sensor can also be recorded for documen‐tation purposes using a recorder. To do so, connect the recorder tothe standard output of the control.You can select between a standard signal of 0... 20 mA and 4 ... 20mA:

n 0 or 4 mA corresponds to the sensor signal 0 W/m2.n The 20 mA can be assigned to any maximum W/m² value (0

W/m² ... 999 W/m²).

5.10.10 Analogue input XE2The analogue input XE2 is permanently related to the flow. Youmay select 0 ... 20 mA or 4 ... 20 mA.The measured value is displayed in the secondary display and inthe log book, and is also archived on the SD card.

5.10.11 Analogue input XE3Analogue input XE3 may be used for turbidity measurement ormeasuring the combined chlorine. You may select 0 ... 20 mA or4 ... 20 mA. When using inputs for combined chlorine you mayselect this input to set the setpoint of the sensor signal.The measured value is displayed in the secondary display and inthe log book, and is also archived on the SD card.

5.10.12 Temperature input XE4

Maximum operating temperatureTo achieve sufficient rinsing of the UV system, therinse valve must be of sufficient size.In order to prevent the maximum temperature frombeing reached during activation of the rinseprocess, the water temperature in the display mustbe set to a significantly lower temperature than themaximum permissible operating temperature.

To prevent overheating of the UV system if there is no or inade‐quate flow through the UV system, when the maximum operatingtemperature is reached, the rinse valve is opened. If the maximalpermissible water temperature does not fall by approx. 5 °C or ifthe water temperature increases to the maximum temperaturewithin the maximum permissible „rinse time in the event ofexcessive temperature“ , the control switches off the UV lamp andswitches to fault mode.


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5.10.13 Minimum mains voltage

Modifications to the minimum mains voltage mayonly be carried out by the manufacturer.

Monitoring the mains voltage prevents uncontrolled failure of theUV system and the UV lamps due to insufficient mains voltage. Ifthe mains voltage drops to the minimum value, the control switchesto undervoltage mode and the UV system is shut down in a con‐trolled manner. If the mains voltage exceeds the permissible min‐imum value again, the UV system starts up again automatically.

5.10.14 Other inputs and outputs5.10.14.1 Pause

The UV system can be switched on and off by opening and shut‐ting an external contact that is connected to the pause input of thecontroller. It is possible to select whether the UV system starts upwith an open or closed pause contact. The pause contact is atpause. The UV system starts up when the pause contact is open.

5.10.14.2 External fault switch input

The „EXTERNAL FAULT“ switch input is bridgedwhen the system is delivered. When the bridge isremoved without connecting a fault signallingdevice, the controller switches to fault mode. TheUV system can then no longer be operated.

When a fault signalling device is connected,remove the bridge as otherwise no fault will bereported.

An external fault signalling device can be connected to the„EXTERNAL FAULT“ switch input such as e. g. a flow detector.

5.10.14.3 Signal relay operationA signalling device can be connected to the signal relay operation.If the UV system has reached normal operating mode, the signalrelay operation is activated.

5.10.14.4 Alarm signal relayA signalling device can be connected to the signal relay alarm. Thealarm signal relay drops out if there is a fault or in the event of apower failure.


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6 Assembly and Installationn User qualification, mechanical installation: trained and qualified

personnel, see Ä Chapter 2.2 „Users' qualifications“ on page 8n User qualification, electrical Installation: Electrical technician,

see Ä Chapter 2.2 „Users' qualifications“ on page 8

6.1 Reactor

A2474

Fig. 6: ReactorI. InletII. Outlet

6.1.1 Assembly

NOTICE!Maintenance workLeave adequate room for maintenance work.The required clearance for maintenance work, e. g.replacing lamp protection tubes and working on thewiper system, can be found in the measurementsheet.

Fix the reactor in place with appropriate fixing material (pipe clamp,frame). The fitting position can in principle be chosen at randomand, if required, can be adapted to conditions on site. With UV sys‐tems equipped with a wiper, ensure that the wiper can be servicedeasily.

6.1.2 Attaching the Warning Sign and Nameplate to the Reactor

NOTICE!Attach the self-adhesive warning label supplied tothe reactor so that it is clearly visible.

Fitting position

Assembly and Installation

35

Attach the “Caution UV radiation” warning sign and the “160°opening angle” label directly adjacent to the sensor con‐nector.

6.1.3 Hydraulic Connections

CAUTION!Installation regulationsPossibility of incorrect assembly.Carry out hydraulic connection of the reactor inaccordance with the applicable general guidelinesand local installation regulations.

.

Information for appropriate installation– Provide valves upstream and downstream of

the reactor to shut off the reactor for mainte‐nance work.

– It is also recommended with reactors, whichare regularly cleaned by filling them with acleaning solution, that the water drain con‐nector and the vent screw are replaced byappropriate valves.

– With larger reactors, it is recommended thatthey are filled through the water drain openingusing an appropriate acid-resistant pump.

– If the reactor is filled with a pump, it is alsouseful to circulate the cleaning solution throughthe vent opening. This shortens the cleaningtime and achieves a better result.

6.2 Control Cabinet and Control6.2.1 Assembly

NOTICE!Do not lay power cables (lamp cable, mains powerline etc.) and signal cables (sensor connectorcables etc.) together.

Fit the control cabinet or the mounting panel with control and elec‐tronic ballast to the wall or a suitable frame so that the UV lampand UV sensor can be connected to the cables provided.


36

6.2.2 Electrical connections

WARNING!Electrical connectionsPossible consequence: Fatal or very serious inju‐ries.– Please observe all generally applicable guide‐

lines and local installation regulations.– Only carry out installation work on the UV

system if it is disconnected from the mainspower supply.

– Connect a protective earth conductor to thereactor and to the reactor cover. Ensure a con‐tinuous power supply by means of a suitablefault current protection.

– Only an authorised electrical technician mayopen the control cabinet!

– Do not lengthen the connecting cable for theUV lamp or the UV sensor cable.

– The electrical installation must be carried outby an authorised electrical technician using thedocuments supplied (wiring diagram).

6.2.3 Fitting the temperature sensorScrew the temperature sensor, which monitors the water tempera‐ture, into the thread provided for this on the front of the reactor.1. Screw the temperature sensor into the thread until hand-tight.2. Attach the connecting cable and fix in place.

6.2.4 Assembly and connection of the limit switch

NOTICE!Without the limit switch, the wiper motor will notdetect its end positions. This leads to failure of thewiper.

The limit switch is used to monitor the wiper motor.1. Screw the limit switch into the threaded sleeve provided on

the reactor cover.2. Lightly tighten the locking nut.3. Connect the limit switch using the angled plug.


37

6.2.5 Connecting the UV Sensor

Only use food-safe lubricant.The quartz window must not come into contact withlubricant.

1. Guide the O-ring over the thread of the UV sensor up to thesealing groove.

2. Grease the thread of the UV sensor.3. Screw in the UV sensor and lightly tighten.4. Connect the UV sensor using the sensor connection cable.

6.3 Fitting the UV Lamp Protection Tube6.3.1 Fitting the UV lamp protection tube without the wiper

1. Loosen the bracket of the UV lamp protection tube with anAllen key and remove it.

2. Carefully pull the transport protection (grey plastic pipe) com‐pletely out of the reactor.

3. Use the transport protection as an insertion aid. Guide thegrey plastic tube into the UV lamp protection tube until onlyaround 30 cm of the plastic tube is projecting.

4. Carefully push the UV lamp protection tube until it reaches itsstop position in the reactor.

5. Push a new O-ring onto the end of the UV lamp protectiontube.

6.CAUTION!– Check the UV lamp protection tube for

damage before fitting.– Never re-fit a damaged UV lamp pro‐

tection tube.– Ensure that the UV lamp protection tube

is sitting correctly.

6.3.2 Fitting the UV Lamp Protection Tube with Automatic Wiper1. Loosen the bracket of the UV lamp protection tube with an

Allen key and remove it.2. Move the wiper into the service position, service menu: Wiper

positions.3. Carefully push the UV lamp protection tube into the reactor.4. Push a new O-ring onto the end of the UV lamp protection

tube.5. Carefully push the UV lamp protection tube until it reaches its

stop position in the reactor.


38

6.CAUTION!– Check the UV lamp protection tube for

damage before fitting.– Never re-fit a damaged UV lamp pro‐

tection tube.– Ensure that the UV lamp protection tube

is sitting correctly.

7. Screw the UV lamp protection tube tightly into the reactorcover.

ðLeak testFollowing this, check the leak-tightnessof the UV system.

6.4 Assembly and connection of the UV lamps

WARNING!Electrical installationCause: Danger from electrical voltage.Possible consequence: Fatal or very serious inju‐ries.Measure: Prior to assembly and connection of theUV lamps, switch off the master switch or pull themains plug out of the socket.

WARNING!UV-C radiationCause: Danger from UV-C UV radiation.Consequence: UV radiation is harmful to the eyesand skin.Measure: Only start up the UV lamps when theyare properly installed.

NOTICE!Premature UV lamp failureNever touch the UV lamp glass with bare hands.Fingerprints burn into the glass and can result inpremature failure. Use a cloth moistened withalcohol to clean off fingerprints from the lampbefore installation.


39

Install the UV system in accordance with all perti‐nent regulations prior to commissioningWith free-standing UV systems, attach the con‐necting plug with lamp cover to the UV lamp beforethe UV lamp is inserted into the lamp protectivetube.

1. Place the O-ring into the groove provided on the lamp protec‐tion tube holder.

2. Insert the UV lamp into the UV lamp protection tube andallow it to project out approx. 100 mm.

3. Attach the connector plug with lamp cover to the UV lamp.4. Insert the UV lamp fully into the lamp protection tube5. Place the UV lamp cover onto the UV lamp protection tube.

Use an Allen key to screw in the fixing bolts provided andtighten.

6. Attach the pin plug with the lamp connection cable to thesocket on the cover of the lamp and fix in place with theknurled nut.

6.5 Assembly and installation of the wiper motor (optional)1. Push the enclosed protective cover (14) over the wiper rod.2. Connect the wiper motor to the adapter plate using the

mounting kit.


40

7 Commissioningn User qualification, commissioning: trained user, see Ä Chapter

2.2 „Users' qualifications“ on page 8

Avoid frequent switching operationsAvoid short switching intervals and switching oper‐ations. Frequent switching operations can have anegative effect on the service life of the UV lamp.

7.1 Check the control system programming

WARNING!Insufficient water treatmentThe UV transmission of the water must be knownbefore commissioning the UV system.Please read the technical data sheet for your UVsystemEnsure that:– the maximum permissible water flow rate is not

exceeded and– the UV transmission does not fall below the

permissible level,– as otherwise adequate treatment of the

water cannot be guaranteed because theradiation dose is too low.

NOTICE!Warning thresholdFailure to set the warning thresholds in accordancewith the data sheet will lead to warning alerts beinggiven prematurely or late.

Minimum irradiation intensityIt is especially important to check whether the min‐imum radiation intensity is set in accordance withthe information in the accompanying data sheet. Ifthe minimum radiation intensity is undershot on aregular basis or is permanently undershot, theneither the max. flow should be reduced or a waterpretreatment process must be installed upstreamin order to improve the water transmission value ofthe UV system.

Commissioning

41

7.2 Leak testing and ventilation of the reactor1. Open the bleed valve on the reactor.2. Slowly open the shut-off valve upstream of the reactor.3. Fill the reactor until water emerges from the bleed valve.4. Close the bleed valve.5. Check the reactor for leaks.6. Open the shut-off valve downstream of the reactor (only nec‐

essary with a manual shut-off valve).

7.3 Switching on the UV SystemIn commissioning status, the UV system’s continuous displayshows the „Warm-up phase“ message.The following symbols appear in the status display:n A downward arrow indicates that the warning threshold has not

been reached.n Two downward arrows indicate that the minimum radiation

intensity has not been reached.n The disc symbol indicates that a SD card has been inserted.The following information appears in the secondary display on anongoing basis:n The remaining warm-up time is displayed.n If available, the temperature is displayed.n If available, the measured values for both analogue inputs are

displayed.1. Switch on the UV system using the [START/STOP] key. In

order to do so, hold down the [START/STOP] key for at least2 seconds

ð The „Warm-up phase“ display appears

2. The „Normal operation“ display appears

ð Once the UV lamps have ignited, it will take severalminutes until the full UV output has been reached.

3. Should an error message appear, evaluate the error mes‐sage, taking into account chapter Ä Chapter 9 „Trouble‐shooting (Faults and Warnings)“ on page 74 in this regard.

4. Set the required control type, see Ä Chapter 7.1 „Check thecontrol system programming“ on page 41

5. Set the minimum radiation intensity and warning threshold inthe control, Ä Chapter 7.1 „Check the control system pro‐gramming“ on page 41ð The UV system is now ready for operation.

7.4 Adjustable functions and parametersMenu Property

Display unit The display unit can only be changed in „Off“ status.

Transfer pump control The transfer pump control can only be changed in „Off“ status.

Commissioning

42

Menu Property

Minimum radiation intensity This menu only appears with UV systems for which no control has beenprovided.

Warning threshold This menu only appears with UV systems for which no control has beenprovided.

Maximum rinsing time The maximum rinsing time can only be changed in „Off“ status.

Maximum free rinse time The maximum rinse-free time can only be changed in „Off“ status.

Lamp post-burn time The lamp post-burn time can only be changed in „Off“ status.

Set date The date and time can only be changed in „Off“ status. The Europeandisplay format is used for both parameters.

Set time

Measured value recording The measured value recording shows the time intervals at which themeasured values are entered into the log book.

Control Only with UV systems that support the control functionn No controln Manual controln External control

Analogue output XA1 The analogue output is used for issuing the radiation intensity. The ana‐logue output shows the display value as a current signal.

Analogue input XE2 The analogue input XE2 is permanently related to the flow. The ana‐logue input XE2 can be used to control the radiation intensity.The measured value is displayed in the secondary display and in the logbook, and is also archived on the SD card.

Analogue input XE3 Various measured values can be assigned to the analogue input XE3.The measured value is displayed in the secondary display and in the logbook, and is also archived on the SD card.

Temperature input XE4 The operating temperature is used to monitor the water temperature inthe reactor. The setting value is limited by the maximum water tempera‐ture, which can only be adjusted in the configuration menu.The measured value is displayed in the secondary display and in the logbook, and is also archived on the SD card.

Commissioning

43

8 Maintenance8.1 General Information

n User qualification: trained user, see Ä Chapter 2.2 „Users'qualifications“ on page 8

WARNING!UV-C radiationPossible consequence: Serious injuries.UV-C radiation is harmful to the eyes and skin.– Only operate the UV lamp UV-C when it is fully

fitted and installed.– Install the UV lamp in the UV system in accord‐

ance with the regulations prior to commis‐sioning.

WARNING!Live parts!Possible consequence: Fatal or very serious inju‐ries– Measure: Disconnect the device from the


devices that have been tampered with from thepower supply.

CAUTION!General precautionary measuresEnsure that the reactor is at atmospheric pressurebefore carrying out any maintenance work.

NOTICE!Maximum permissible service lifeReplace the UV lamps at the latest after their max‐imum permissible service life. Otherwise, the oper‐ating safety of the UV system can no longer beguaranteed.The maximum permissible service life is 14,000operating hours, unless otherwise stated in theaccompanying data sheet.

Maintenance

44

NOTICE!Chemical cleaning processesNote the following with UV systems integrated intochemical cleaning processes (CIP):– Do not use any corrosive cleaning chemicals,

e.g. HCl (hydrochloric acid).– The maximum temperature of the CIP process

may not exceed the following values:– 90 °C with alkaline cleaning media.– 50 °C with acidic cleaning media.

– Switch off the UV system during the CIPprocess.

Maintenance of the UV system is limited to cleaning the UVsensor/UV sensor window and replacing the UV lamp at the end ofits maximum permissible service life.An operating log must be maintained to document any mainte‐nance work carried out; a form is included in the Appendix.

8.2 Cleaning with a WiperIn UV systems with automatic wiper, the lamp protection tubed iscleaned in situ according to the set wiper interval (default setting 2h).

In UV systems with manual wiper, the UV lamp protection tubesare cleaned in situ as required.

8.3 Cleaning with Cleaning Solution by Filling the UV System

NOTICE!Handling the cleaning solution– It is also recommended with reactors, which

are regularly cleaned by filling them with acleaning solution, that the water drain con‐nector and the vent screw are replaced byappropriate valves.

– With larger reactors, it is recommended thatthey are filled through the water drain openingusing an appropriate acid-resistant pump.

– If the reactor is filled with a pump, it is alsouseful to circulate the cleaning solution throughthe vent opening.– This shortens the cleaning time and ach‐

ieves a better result.– If the cleaning solution is collected and stored

in a suitable storage tank, it can be reused sev‐eral times.

1. Switch off the UV system.2. Switch off the master switch or disconnect it from the mains

power supply.

Cleaning with an automatic wiper

Cleaning with a manual wiper

Cleaning the lamp protection tubes byfilling the reactor with a cleaning solu‐tion:

Maintenance

45

3. Close the shut-off valves upstream and downstream of theradiation chamber.

4. Drain the reactor.5. Screw in the water drain screw again and tighten using min‐

imal force.6. Fill the reactor with the cleaning solution through the vent

opening.

ð Allow the cleaning solution to work for at least 20minutes.

7. Open and remove the water drain screw.8. Empty the reactor and dispose of the cleaning solution in

accordance with the applicable regulations.9. Flush the reactor thoroughly with clean water until all residue

of cleaning solution has been removed.10. Screw in the water drain screw and tighten using minimal

force.11. Slowly open the shut-off valve upstream of the reactor.12. Fill the reactor until water emerges from the vent screw.13. Close the air vent screw and tighten it using minimal force.14. Open the shut-off valve downstream of the reactor, which is

only necessary with a manual shut-off valve.

ð Check the reactor for leaks.

15. Switch on the master switch or connect to the mains powersupply.

ð The UV system is ready for operation again.

8.4 Cleaning the UV lamp protection tube and replacing the wiper element

NOTICE!Clean the UV lamp protection tubes and replacethe wiper element - after 1000 wiper cycles at thelatest.Clean the tube when the UV sensor signal fallsbelow the warning threshold, without this beingbased on other causes, such as ageing of the UVlamp or significant worsening of the UV transmis‐sion, after 1000 wiper cycles at the latest. In addi‐tion, the wiper element (if present) must always bereplaced.

Maintenance

46

CAUTION!Unsuitable cleaning agentsPossible personal injury / material damage to UVsystems.– Do not use any acids that are corrosive or that

cause stress cracks, such as hydrochloric acid.– Read the safety data sheet for the cleaning

agent selected.– Wear protective clothing when cleaning (pro‐

tective eyewear, protective gloves ...).– Ensure that no cleaning solution penetrates the

UV lamp protection tube.– When cleaning UV systems, ensure that no

cleaning solution enters the pipework.

NOTICE!Disposal of cleaning agentPossible environmental hazard.Dispose of the waste cleaning solution in accord‐ance with the pertinent guidelines and regulations.Read the safety data sheet for the cleaning agentselected.

An annual clean of the UV lamp protection tubes when replacingthe UV lamp suffices for many UV systems. Clean more frequentlywhen operating with types of water that have a tendency tobecome dirty. The UV lamp protection tubes can be cleaned man‐ually when dismantled or can be cleaned by filling the reactor witha cleaning solution.

8.5 Dismantling and Cleaning the UV Lamp Protection Tube and Sensor

WARNING!UV-C radiationPossible consequence: Serious injuries.UV-C radiation is harmful to the eyes and skin.– Only start up the UV lamp UV-C when it is prop‐

erly installed.– Install the UV lamp into the UV system in

accordance with the regulations prior to com‐missioning.

Maintenance

47



devices that have been tampered with from themains power supply.

CAUTION!Fingerprints on the UV lampPossible consequence: Premature failure of theUV lamp.– Only touch the glass of the UV lamp when

wearing cotton gloves.– Fingerprints or impurities burn into the glass

and can result in premature failure.– For this reason always clean the lamp thor‐

oughly with a cloth moistened with alcoholbefore installing it.

– Then wipe the UV lamp with a soft, dry cloth.

Cleaning the UV sensorClean the UV sensor every time you clean the UVlamp protection tube.

1. Switch off the UV system.2. Position the wiper: activate the wiper in the control in the

„Service“ > „Position wiper“ menu.

ð The wiper moves into the service position.

3. Close the shut-off valves upstream and downstream of thereactor.

4. Switch off the main switch or disconnect from the mainspower supply.

5. Empty the reactor.6. Depending on the system size, now first remove the wiper

motor.7. Remove the safety switch of the UV lamp cover.

WARNING!Hot UV lampPossible consequence: Skin burns.Measure: Switch off the UV system 5 minutesbefore carrying out maintenance work.

8. Use an Allen key to loosen the fixing bolts of the UV lampcover and remove the UV lamp cover and the UV lamp.

9. Place the UV lamp cover and the UV lamp fully to one side.

Cleaning after dismantling the UVlamp protection tube

Maintenance

48

10. Loosen the UV lamp protection tube with a face spanner andremove it, placing it on the holes, not on the threads.

11. Carefully fully remove the UV lamp protection tube from thereactor and place on a suitable clean surface.Use the insertion aid for this (grey plastic tube). Guide thegrey plastic tube into the UV lamp protection tube until onlyaround 30 cm of the plastic tube is projecting.

12. Remove the O-ring from the lamp protection tube.13. Wash the UV lamp protection tube with cleaning solution or

immerse it in cleaning solution until the film has beenremoved without leaving a trace.

14. Rinse the UV lamp protection tube with clean water and drythoroughly with a soft cloth.

15. Loosen the sensor connection cable from the UV sensor.16. Rotate the UV sensor out of the reactor.17. Clean the quartz window with a cloth that has been saturated

with cleaning solution until the coating has been removedwithout leaving a trace.

18. Rinse the quartz window with clean water and dry with a softcloth.

19. Fit a new O-ring.20. Screw in the UV sensor again and tighten using minimal

force.21. Connect the sensor connection cable to the UV sensor.22. Use the transport protection as an insertion aid. Guide the

grey plastic tube into the UV lamp protection tube until onlyaround 30 cm of the plastic tube is projecting.

23. Carefully push the UV lamp protection tube until it reaches itsstop position in the reactor.

24.CAUTION!Check the UV lamp protection tube fordamage before fitting– Never re-fit a damaged UV lamp protec‐

tion tube.– Ensure that the lamp protection tube is

sitting correctly.

Push a new O-ring onto the end of the UV lamp protectiontube.

Condition of the O-ringCheck whether the O-ring on the UV lampprotection tube bracket is seated in thegroove provided. Ensure that the sealing sur‐faces on which the O-ring sits are completelysmooth and clean.

Cleaning the UV sensor

Fitting the UV lamp protection tube

Maintenance

49

25. Screw the UV lamp protection tube into the reactor cover.

Leak testFollowing this, check the leak-tightness of theUV system.

26. Attach the connector plug with lamp cover to the UV lamp.27. Insert the UV lamp fully into the lamp protection tube28. Place the UV lamp cover onto the UV lamp protection tube.

Use an Allen key to screw in the fixing bolts provided andtighten.

29. Attach the pin plug with the lamp connection cable to thesocket on the cover of the lamp and fix in place with theknurled nut.

30. Depending on the system size, first fit the wiper motor.31. Attach the pin plug with the connection cable for the motor

wiper to the wiper motor socket and fix in place with theknurled nut.

32. Connect the cable plugs for the solenoid switch and tempera‐ture monitor.

33. Switch on the main switch or connect up to the mains powersupply.

34. Slowly open the shut-off valve upstream of the reactor.35. Open the shut-off valve downstream of the reactor, which is

only necessary with a manual shut-off valve.36. Switch on the UV system.

Maintenance

50

8.6 Maintaining the wearing parts of the automatic wiper8.6.1 Tools

A1874

Fig. 7: ToolsTools:n 8 mm open-ended spannern 9 mm open-ended spannern 10 mm open-ended spannern 13 mm open-ended spannern 16 mm open-ended spannern 18 mm open-ended spannern 19 mm open-ended spannern 22 mm open-ended spannern 24 mm open-ended spannern 27 mm open-ended spannern 32 mm open-ended spannern 1.5 mm Allen keyn 2 mm Allen keyn 3 mm Allen keyn 4 mm Allen keyn 5 mm Allen keyn 300 gramme hammern Plastic hammern Straightedge / calipersn Screw driver, Philipsn Cotton glovesn Dulcodes LP special tool (supplied with UV system delivery).

Maintenance

51

8.6.2 Replace these wearing parts after 1000 wiper cycles, earlier if necessary

Spare parts kitThis chapter describes all the working stepsneeded to individually or completely replace all thecomponents in the spare parts kit.There are different spare parts kits depending onthe number and type of UV lamps fitted:– Part number 1059074: Spare parts kit 2x350

W / motor wiper– Part number 1059075: Spare parts kit 3x350

W / motor wiper– Part number 1074886: Spare parts kit 4x350

W / motor wiper

A2248

Fig. 8: Replace these wearing parts after 1000 wiper cycles, earlierif necessary. The number of components varies depending on thetype of the spare parts kit.

8.6.3 Instructions: Replacing the wearing parts

WARNING!Live parts!Possible consequence: Fatal or very serious inju‐ries– Measure: Disconnect the device from the



– Do not modify the fitted UV lamp connectioncable without authorisation.

Maintenance

52

WARNING!Consequence: Serious injuries.UV-C radiation is harmful to the eyes and skin– Only start up the UV lamp UV-C when it is prop‐



CAUTION!Fingerprints on the UV lampPossible consequence: Premature failure of theUV lamp– Only touch the glass of the UV lamp when


and can result in premature failure– For this reason always clean the lamp thor‐



CAUTION!High weight componentsSince individual parts in the UV system exceed thelimit values for lifting and carrying, we recommendthe use of a suitable lifting aid. Observe thenational and company regulations relating to "liftingand carrying" while doing this.

Maintenance

53

1.

A2283

Fig. 9: Assembly aids (1.) 2 units.The two assembly aids provided can be used to facilitate theassembly process if required. These assembly aids are screwedinto the reactor threads and guide the reactor cover duringassembly.

1. Move the wiper into the end position by activating a wipercycle manually and then switch the UV system off once thewiper has reached the end position.

ð The wiper is then located at the extreme end of thespindle.

2. Use the START/STOP key to switch off the UV system.Switch the main switch off or disconnect the mains plug fromthe power supply.

3. Close the shut-off valves upstream and downstream of thereactor.

4. Drain the reactor by removing the upper and lower sealingstoppers.

Dismantling

Maintenance

54

A2203

Fig. 10: Earthing cable5. Remove the earthing cables

A2204

Fig. 11: Flange plate6. Dismantle the flange plate with the wiper motor.

A2205

Fig. 12: UV lamp cover7. Loosen the fixing bolts on the UV lamp cover.8. Remove the UV lamp cover and the UV lamp.

Maintenance

55

A2260

Fig. 13: Bracket (arrow) for UV lamp protection tube9. Loosen the bracket (arrow) with an Allen key and remove the

bracket (arrow) for the UV lamp protection tube.

A2008

Fig. 14: UV lamp protection tube10. Remove the UV lamp protection tube from the reactor.11. Rinse the UV lamp protection tube with clean water and thor‐

oughly dry the UV lamp protection tube with a soft cloth.Chemically clean the UV lamp protection tube if necessary.

Maintenance

56

A2209

Fig. 15: Wiper limit switch12. Remove the cable from the wiper limit switch.

A1885

Fig. 16: Coupling / Splint13. Remove the coupling and remove the splint.

A1886

Fig. 17: Spacer ring / Slip washer14. Remove the spacer ring and the slip washer.

Maintenance

57

A1887

Fig. 18: Bearing cover15. Unscrew the screws on the bearing cover.

A1889

Fig. 19: Bearing cover16. Remove the bearing cover from the reactor cover.

A1890

Fig. 20: X-ring17. Remove the old X-ring and clean all components.18. Grease the new X-ring using CARBAFLO® 2371 and insert

the new X-ring into the reactor cover.

Maintenance

58

A1891

Fig. 21: Checking19. Check and if necessary replace the adapter shaft. The shaft

should not have any grooves or unevenness.

A2282

Fig. 22: Bearing cover / reactor cover20. Fix the bearing cover to the reactor cover.

A2261

A2261

Fig. 23: Screws / reactor cover21. Remove the reactor cover screws.

Maintenance

59

A2262

Fig. 24: Reactor cover22. Remove the reactor cover with the wiper unit.23. Remove the wiper assembly with the spindle, using a lifting

device for this purpose if necessary.

Maintenance

60

A1895

Fig. 25: Wiper spindle

A1896

Fig. 26: Wiper spindle24. Remove the wiper assembly from the wiper spindle.

Maintenance

61

A1447

Fig. 27: Tool for the threaded sleeve in the wiper mounting, partnumber 1037738

A1897

Fig. 28: Checking the threaded sleeve

A1898

Fig. 29: Unscrewing the threaded sleeve

Maintenance

62

A1899

Fig. 30: Checking the threaded sleeve25. Check and if necessary replace the threaded sleeve in the

wiper mounting.

A1901

Fig. 31: Plastic slide bearing

A2210

Fig. 32: Plastic slide bearing26. Check and if necessary replace the plastic slide bearings.

Maintenance

63

A1903

Fig. 33: Bearing cover27. Open the bearing cover to obtain access to the slide bearing.

Maintenance

64

A1450

auspressen einpressen

Fig. 34: Tool for pressing the plastic slide bearings in and out, partnumber 1036907

A1904

Fig. 35: Bearing cover, slide bearing

A1905

Fig. 36: Bearing cover, slide bearing28. Replace the slide bearing of the bearing cover.

Maintenance

65

A1906

Fig. 37: Bearing cover29. Close the bearing cover.

A1907

1.

Fig. 38: Wiper element (1)30. Check and if necessary replace the wiper element (1).

The wiper lip points away from the reactor cover, to facilitateinsertion of the UV lamp protection tube.

ð When assembled, the wiper element should be mountedso it floats and can move.

Maintenance

66

A2279

70

69

Fig. 39: Wiper locknut (69) and slide bearing (70)31. Remove the splint securing the wiper locknut (69).

Replace the wiper locknut (69) and insert a new splint.32. Replace the slide bearing (70).

A2211

Fig. 40: Bearing cover / reactor cover33. Screw the bearing cover to the reactor cover using the

screws.

ð The flat area points towards the UV lamp

Replacing the wiper locknut and slidebearing after 5 years

Reassembling the unit

Maintenance

67

A2265

Fig. 41: Reactor cover34. Slide the reactor cover with the wiper rod onto the reactor,

using a lifting device for this purpose if necessary.

A2212

Fig. 42: UV lamp protection tube / O-ring35. Fit the UV lamp protection tube using a new O-ring. Screw

the UV lamp protection tube bracket into the reactor coveruntil hand-tight.

Maintenance

68

A2260

Fig. 43: Bracket (arrow) for UV lamp protection tube36. Screw down the UV lamp protection tube bracket (arrow).37. Fit the UV lamp.

A1940

Fig. 44: Coupling38. Attach the slip washer, the spacer ring and feather key and fit

the couplingSecure the spacer ring. Place the coupling on gently, do nottighten the screw firmly.

Maintenance

69

A1913

Fig. 45: Wiper motor onto the coupling39. Place the wiper motor onto the coupling

Position the coupling and tighten the screw.

A2215

Fig. 46: Protective cover over the coupling40. Remove the wiper motor, push the protective cover over the

coupling. Then push the wiper motor onto the coupling againand fix the wiper motor in place.

41. Connect up all electrical connections.42. Seal the reactor by screwing in the upper and lower sealing

stoppers.43. Slowly open the shut-off valves upstream and downstream of

the reactor, fill the reactor with water and vent the reactor asnecessary.

44. Switch the main switch on and/or connect the mains plug tothe power supply.

45. Switch the UV system on.46. Assemble the UV system in reverse order.

ð Note the information in the operating instructions.

Restart the UV system

Maintenance

70

8.7 Replacing the lamp




WARNING!UV-C radiationPossible consequence: Serious injuries.UV-C radiation is harmful to the eyes and skin.– Only start up the UV lamp UV-C when it is prop‐



WARNING!Insufficient treatment efficiencyPossible consequence: Illness.Please read the Technical Data Sheet accompa‐nying your UV system.– Replace the UV lamps with new lamps at the

very latest when:– The UV sensor signal approaches the min‐

imum radiation intensity without this beingdue to other causes, such as the formationof a coating on the UV lamp protectiontubes or a serious deterioration of the UV-transmission.

– The operating life of the UV lamp isapproaching the maximum service life ofthe lamp or has exceeded it.

CAUTION!Fingerprints on the UV lampPossible consequence: Premature failure of theUV lamp.– Only touch the glass of the UV lamp when


and can result in premature failure.– For this reason always clean the lamp thor‐



Maintenance

71

NOTICE!Clean the lamp protection tubes each time a lampis replaced.Dispose of used lamps in accordance with theapplicable guidelines and directives. Usually theycan be disposed of together with used fluorescenttubes.

1. Deactivate the UV system.2. Switch off the master switch or disconnect it from the mains

power supply.3. Close the shut-off valves upstream and downstream of the

reactor.4. Loosen the fixing bolts of the lamp cover using an Allen key,

remove the lamp cover and pull out the lamp by approxi‐mately 100 mm.

5. Loosen the UV lamp at the cable clamp with the aid of aslotted head screw driver.

6. Fully remove the UV lamp and place it to one side.7. Check whether the O-ring on the UV lamp protection tube

bracket is in the groove provided – ensure that the sealingsurfaces of the O-rings are completely smooth and clean.

8. Fix the UV lamp to the cable clamp with the aid of a slottedhead screw driver.

9. Insert the UV lamp fully into the UV lamp protection tube.10. Place the UV lamp cover onto the UV lamp protection tube

bracket and, using the fixing bolts provided, screw in andtighten with an Allen key.

11. Switch on the main switch or connect up to the mains powersupply.

12. Switch on the UV system.13. Slowly open the shut-off valve upstream of the reactor.14. Open the shut-off valve downstream of the reactor (only nec‐

essary with a manual shut-off valve).15. Delete the lamp data in the controller.

WARNING!Insufficient treatment efficiencyPossible consequence: Death or illness.Check minimum radiation intensity and warningthreshold.Check and, if necessary, reset the minimum radia‐tion intensity and warning threshold when the UVlamp is replaced.Only a correctly adjusted minimum radiation inten‐sity will guarantee adequate treatment.

Maintenance

72

8.8 Calibrating the UV sensorCalibrate the UV sensor according to the instructions in ChapterÄ Chapter 5.9.1 „Calibration factor“ on page 25.

Maintenance

73

9 Troubleshooting (Faults and Warnings)The display can be in W/m2 or J/m2 depending on the setting.

A2233

Acknowledge fault with OK

Fault

E01-1: external Fault

Time:

Fault1.

Fig. 47: Fault ➔ Acknowledge [OK] ➔ UV system [Off] (0.0 W/m2) / Lamp cool-down period countdown

1.

The two dots indicate that there is a second display for this fault and that you can move to it with the[ i ]key.

LED Function

Red LED The system is in fault mode

Yellow LED The system has warning messages

Green LED The system is in operation

The SD card is in its socket and is active.

The display in the [Fault] state

Troubleshooting (Faults and Warnings)

74

9.1 Warning messagesWarning messages

Warning message Possible cause Remedy

Wiper is faulty. No response from the pulsecounter

Check cabling

The limit switch for the home posi‐tion of the wiper motor does notswitch

Check wiper motor (electrical and hydraulic)and replace if necessaryPerform a functional check of the limit switchand replace the limit switch if necessaryCheck the position of the wiper and the limitswitch on the wiper mechanism

Wiper motor defective The wiper motor produces a faultmessage, which may have the fol‐lowing causes:n Excessive temperaturen Undervoltagen Power limitationn Lock protection in controlled

mode

With a pending warning, the UV system con‐tinues to operate without the wiper being trig‐gered.

Temperature sensormissing.

No temperature sensor connected. Connect temperature sensor.

Temperature sensor defective. Replace temperature sensor.

Temperature sensor cable con‐nection defective.

Check and repair cable connection.

Undervoltagethreshold undershot.

Power supply unstable. Check and repair power supply.

Dimension power supply adequately.

Mains voltage too low. Power supply unstable. Mainsvoltage below the minimumrequired voltage.

Check and repair power supply.

Dimension power supply adequately.

SD card not inserted. SD card not in slot. Insert SD card into the slot.

SD card defective. Replace SD card.

SD card is locked. The slider on the SD card is set to"LOCK".

Unlock SD card.


SD card is full. SD card memory is full. Back up the data externally and clear the SDcard memory.


The operating time ofUV lamp X hasexpired.

The maximum permissible usageperiod of UV lamp X has beenreached.

Replace UV lamp.

Warning threshold notreached

The sensor signal is below thewarning threshold:

Lamp output too low Increase lamp output. For UV systems withmanual step control, increase the output withthe rotary dial.

Deposit formation on the lamp pro‐tection tube and/or the UVCsensor

Trigger wiper cycle; clean lamp protectiontube and/or UV sensor if necessary


75

Warning message Possible cause Remedy

Deterioration of the UV transmis‐sion of the water to be treated

Improve water quality by suitable pretreat‐ment

UV lamp at the end of its servicelife

Replace UV lamp

UV sensor not calibrated Check UV sensor and if necessary, calibrateor replace UV sensor

XE2: Current < 4 mA The current at the signal input isbelow 3.6 mA.

Check and repair cable connection.

Check and repair connected measuringdevices.

XE3: Current < 4 mA

Temperature too high The maximum set operating tem‐perature is exceeded.

Water temperature is above the maximum settemperature. A flushing process is triggered. Ifthe temperature does not decrease within thewater cooling time of 5 min., the UV systementers Fault status.


76

9.2 Fault messages

Acknowledging a fault messageThe UV system is immediately switched off in theevent of a fault. You can acknowledge this faultwith the [OK] button.Once you have acknowledged a fault, the UVsystem switches from the [Fault] mode to [Off]mode. Before starting up the UV system, checkwhether any troubleshooting measures imple‐mented have been successful. A restart makessense only if all fault-related errors have been rec‐tified.

Fault messages

Fault messages Possible cause Remedy

E01-1: External fault The "External fault" digitalinput responds.

Eliminate cause of external fault.

No external fault indicatingdevice connected.

Bridge contacts at fault input.

E02-1: Excessive tem‐perature

The maximum permissiblewater temperature of 65°Chas been exceeded.

Lower water temperature of the process.

E03-1: Water cooling-down time has beenexceeded

The maximum set operatingtemperature continues to beexceeded after automaticflushing process.

Lower water temperature of the process.

E04-1: Radiation inten‐sity too low

The sensor signal is below the minimum radiation intensity:

Lamp output too low. Increase lamp output.

Deposit formation on thelamp protection tube and/orthe UV sensor/sensorwindow.

Trigger wiper cycle; clean lamp protection tubeand/or UV sensor/sensor window.

Deterioration of the UV trans‐mission of the water to betreated.

Improve water quality by suitable pretreatment.

UV lamp at the end of itsservice life.

Replace UV lamp.

UV sensor not calibrated. Check UV sensor and if necessary, calibrate orreplace UV sensor.

Faulty setting of the warningthreshold or minimum radia‐tion intensity.

Check warning threshold or minimum radiationintensity and adjust if necessary.

Electronic ballast defective. Replace electronic ballast.

Electrical contact problems. Check terminals in the control cabinet, lamp con‐nection terminals and lamp cable and repair ifnecessary.

*X = Number of components, e. g. UV lamp number 5.**EB = Electronic ballast.


77

Fault messages Possible cause Remedy

E08-1: UV sensor < 10mV

Sensor voltage less than the minimum permissible sensor voltage:

UV sensor defective. Replace UV sensor.

Electrical contact problems. Check terminals in the control cabinet and sensorcables and repair if necessary.

E06-1: XE2: Flow < 4mA

Signal input activated as con‐troller variable.

No device connected to signal input.Cable break.External device or UV controller mA input incor‐rectly configured.

The current at the signal inputis below 3.6 mA.

E07-1: XE2: Setpoint <4 mA

Signal input activated as con‐troller variable.

No device connected to signal input.Cable break.External device or UV controller mA input incor‐rectly configured.

The current at the signal inputis below 3.6 mA.

E01-2: Fault in EB** X* Supply voltage at EB** X*outside the permissiblerange.

Check supply voltage and stabilise if necessary.

Check cabling and repair if necessary.

E02-2: Fault in EB** X* Fault in UV lamp X*. Check cabling and repair if necessary.

Replace UV lamp.

Replace EB**.

E03-2: Earth leakageat EB** X*

Earth leakage at EB** X*. Check cabling and repair if necesary.

Replace EB**.

E04-2: Temperature atEB** X*

Maximum permissible tem‐perature at EB** exceeded.

Check fan for EB** X* cooling and repair if neces‐sary.

Check fan fuse and repair if necessary.

E05-2: Time out atEB** X*

No communication betweenUV system controller moduleand EB** X*.

Check cabling between controller module andEB** X* and repair if necessary.

Replace EB** X*.

Replace controller module.

*X = Number of components, e. g. UV lamp number 5.**EB = Electronic ballast.


78

10 Technical Data

NOTICE!Data sheetThis technical data supplements the enclosed datasheet. If in doubt, the information on the data sheetapplies.

Type Number of lamps Lamp power Connected power

1x230 W 1 260 W 310 W

1x350 W 1 370 W 430 W

2x350 W 2 2x370 W 835 W

3x230 W 3 3x260 W 825 W

3x350 W 3 3x370 W 1240 W

4x350 W 4 4x370 W 1645 W

6x350 W 6 6x370 W 2455 W

Type Minimum clearance forMaintenance work per‐formed

Empty weight /Operating weightReactor

Volume in litresGrossNet

1x230 W 1065 mm 19 kg / 32 kg 14.8 / 13.5

1x350 W 1465 mm 30 kg / 60 kg 30.8 / 29.0

2x350 W 1465 mm 56 kg / 128 kg 72.4 / 68.8

3x230 W 1065 mm 65 kg / 139 kg 82.6 / 78.8

3x350 W 1570 mm 84 kg / 219 kg 135.9 / 130.4

4x350 W 1570 mm 96 kg / 259 kg 164.3 / 156.7

6x350 W 1570 mm 137 kg / 347 kg 213.4 / 201.9

Permissible operating temperatures:n Water temperature: 2 ... 40 °Cn Ambient temperature: 5 ... 40 °CRequirements of the water to be treated:n Maximum temperature: 40 °Cn Maximum operating pressure: 10 barn No corrosive or abrasive properties, chloride content < 250

ppmn No tendency for sedimentation

10.1 Setting DataRefer to Ä Chapter 5.4 „Adjustable parameters / accesscode“ on page 20

Performance data

Technical Data

79

10.2 Control Cabinet

Wiring diagram providedA system-specific wiring diagram (appendix) issupplied with the UV system. In the event of anydifferences between the operating instructions andsystem-specific wiring diagram, the system-specificwiring diagram applies.

Fuse Current strength Function

F6 1.6 ampere / time-delay For internal electronics modules.

F4 3.1 ampere / time-delay For connected relay GN.

F2 3.1 ampere / time-delay For 3 connected outputs.

Fuses

Technical Data

80

Nominal voltage

230 V AC ± 10%

50/60 Hz

Contact inputs (XK2, XK3, XK4):

for contacts or switching transistors:

Output voltage: maximum 9 V

Contact resistance open > 100 kOhm / contact resistance closed < 100 kOhm

Output relay, feeding, XR3

Type of contact: N/O

Load capacity: 90 ... 253 V AC / 3 A / maximum 690 VA

Provide RC protection circuits with inductive loads!

Relay outputs XR1:

Type of contact: N/O, potential-free

Load capacity: 90 ... 253 V AC / 3 A / maximum 690 VA

Load type: Ohmic and inductive loads (up to power factor (cos phi) = 0.4)

Alarm relay XR2:

Type of contact: Changeover contact, potential-free

Load capacity: 90 - 253 V AC / 3 A / maximum 690 VA

Provide RC protection circuits with inductive loads!

Standard signal output mA (-X3:7 ... -X3.8):

0/4...20 mA, potential-free

Maximum load: 450 Ohm at 21.5 mA

Degree of protection:

Degree of protection: IP 66

Control Cabinet

Technical Data

81

11 Dimensional drawing11.1 Dimensional drawing Dulcodes LP 1x230W ... 6x350W

A2239

Fig. 48: Dimensional drawing Dulcodes LP 1x230W ... 6x350W.

Dimensional drawing Dulcodes LP 1x230W ... 6x350W

Type 1x230W 1x350W 2x350W 3x230W 3x350W 4x350W 6x350W

DN 80 100 150 150 200 200 250

B1 600 600 600 600 600 760 760

B2 630 630 630 630 630 790 790

H1 760 760 760 760 760 760 760

H2 702 702 702 702 702 702 702

T1 210 210 210 210 210 300 300

T2 247 247 247 247 247 337 337

Ø D1 10.2 10.2 10.2 10.2 10.2 10.2 10.2

Ø D2 139.7 168.3 256 323.9 323.9 355.6 406.4

Ø D3 88.9 114.3 168.3 168.3 219.1 219.1 273

Ø TK 160 180 240 240 295 295 350

L1 67 122 122 101 130 130 130

L2 1053.5 1522.5 1495.5 1040.5 1715 1715 1688

L3 1151 1640 1640 1185 1885 1885 1885

L4 1190 1679 1679 1224 1924 1924 1924

LS 609 881 881 643 1007 1007 1007

LF 138.5 198 242 276 276 292 317

LA 2215 3105 3105 2250 3450 3450 3450

Dimensional drawing

82

11.2 Dimensional drawing Dulcodes LP 1 ... 4x350W with automatic wiper

A2240

Fig. 49: Dimensional drawing Dulcodes LP 1 ... 4x350W. with automatic wiper

Dimensional drawing Dulcodes LP 1 ... 4x350W with automatic wiper

Type 1x350W 2x350W 3x350W 4x350W

DN 100 150 200 200

B1 600 600 600 760

B2 630 630 630 790

H1 760 760 760 760

H2 702 702 702 702

T1 210 210 210 300

T2 247 247 247 337

Ø D1 10.2 10.2 10.2 10.2

Ø D2 --- 256 323.9 355.6

Ø D3 --- 168.3 219.1 219.1

Ø TK --- 240 295 295

L1 --- 122 130 130

L2 --- 1495.5 1715 1715

L3 --- 1677.5 1924.5 1926.5

L4 --- 1800.5 2047.5 2049.5

LG --- 448 528 560

LS --- 881 1007 1007

LF --- 249 285 301

LA --- 3148 3495 3497

Dimensional drawing

83

12 Appendix12.1 Spare parts, UV system, without wiper12.1.1 Spare parts, 230 W, single lamp system without wiper

A2477

A

9117

5

9

19

13212

11

20

23

11

22Fig. 50: Spare parts, 230 W, single lamp system without wiper

Spare parts list, 230 W, single lamp system without wiper

No. Description Spare partsnumber

Replacementinterval

No.

2 Lamp socket, Æ74x16, 1.4404 1049341 As necessary 1

3 Lamp cover, Æ73x9, 1.4404 1049343 As necessary 1

4 Retainer, Æ48.5/39x3, PTFE REI 1035074 As necessary 1

5 Lamp protection tube with seal 1058838 3 years 1

7 UV lamp, 230 W 1061752 14,000 hours 1

9 Locking screw, DIN 910, G 1/4A 1002752 As necessary 1

11 O-ring/M 10.50 - 1.50, EPDM/P 1001356 After each opening 1


19 Male socket, PG9, 3+PE, Series 69 1017625 As necessary 1

20 O-ring/M, 33.05 - 1.78, EPDM/P 1023570 After each opening 1

22 UVC sensor, G 1” 1062329 As necessary 1

23 Temperature sensor, PT1000, G1/4" 1059076 As necessary 1

30 Lamp cover with plug, UV-LP 230 + 350 1075127 As necessary 1

Appendix

84

12.1.2 Spare parts, 1x350 W, single lamp system without wiper

A2477

A

9117

5

9

19

13212

11

20

23

11

22Fig. 51: Spare parts, 350 W, single lamp system without wiper

Spare parts list, 1x350 W, lamp system without wiper


Replacement interval No.



4 Retainer, Æ48.5/39x3, PTFE 1035074 As necessary 1


7 UV lamp, 350W 1061418 14,000 hours 1




19 Male socket, PG9 3+PE, Series 69 1017625 As necessary 1





Appendix

85

12.1.3 Spare parts, 2x350 W, UV two lamp system without wiper

A2478

B

2

22

3

19

412 57

911

232811

3220

6

20

911

B

Fig. 52: Spare parts, 2x350 W, UV two lamp system without wiper

Spare parts list, 2x350 W, UV two lamp system without wiper


Replacementinterval

No.





6 Bearing ring, Æ50x10, PTFE 1049345 As necessary 1

7 UV lamp 350 W 1061418 14,000 hours 1







23 Temperature sensor, PT1000 G1/4" 1059076 As necessary 1

28 Hexagonal reducer, R 1/2 -Rp 1/4 1003365 As necessary 1


32 Locking screw, IN 910 G 1A 1005766 As necessary 1

Appendix

86

12.1.4 Spare parts, 3x230 W, three lamp system without wiper

A2478

B

2

22

3

19

412 57

911

232811

3220

6

20

911

B

Fig. 53: Spare parts, 3x230 W, three lamp system without wiper

Spare parts list, 3x230 W, three lamp system without wiper







6 Bearing ring, Æ50x10 PTFE 1049345 As necessary 1

7 UV lamp, 230 W 1061752 14,000 hours 1

9 Locking screw, DIN 910 G 1/2A 1005818 As necessary 1









32 Locking screw, DIN 910 G 1A 1005766 As necessary 1

Appendix

87

12.1.5 Spare parts, 3x350 W, three lamp system without wiper

A2478

B

2

22

3

19

412 57

911

232811

3220

6

20

911

B

Fig. 54: Spare parts, 3x350 W, three lamp system without wiper

Spare parts list, 3x350 W, three lamp system without wiper







6 Bearing ring, Æ50x10 PTFE 1049345 As necessary 1

7 UV lamp, 350W 1061418 14,000 hours 1









30 Lamp cover with plug, UV-LP 3...6x350 1075128 As necessary 1


Appendix

88

12.1.6 Spare parts, 4x350 W, UV four lamp system without wiper

A2478

B

2

22

3

19

412 57

911

232811

3220

6

20

911

B

Fig. 55: Spare parts, 4x350 W, UV four lamp system without wiper

Spare parts list, 4x350 W, UV four lamp system without wiper



2 Lamp socket, Æ74x16 1.4404 1049341 As necessary 1

3 Lamp cover, Æ73x9 1.4404 1049343 As necessary 1




7 UV lamp, 350W 1061418 14,000 hours 1




19 Male socket, PG9 3+PE Series 69 1017625 As necessary 1







Appendix

89

12.1.7 Spare parts, 6x350 W, six lamp system without wiper

A2478

B

2

22

3

19

412 57

911

232811

3220

6

20

911

B

Fig. 56: Spare parts, 6x350 W, six lamp system without wiper

Spare parts list, 6x350 W, UV six lamp system without wiper








7 UV lamp, 350W 1061418 14,000 hours 1







23 Temperature sensor PT1000 G1/4" 1059076 As necessary 1




Appendix

90

12.2 Spare parts, single lamp system with wiper12.2.1 Spare parts diagram, single lamp system with wiper

21 20

22 30

23

911

33

34201615

18

A2483

Fig. 57: Spare parts diagram, single lamp system with wiper

Appendix

91

5 7

2

4 23

8391212

11

31

313 19

60

34

35

A

A

A2484


52

49

48

56

57 4450

7011

B

B

D

D

A2485


Appendix

92

17

4055

41

66

67 68

C

C

I.

A2486


Appendix

93

12.2.2 Spare parts list, 3x350 W, single lamp system with wiperNo. Description Spare parts

numberReplacementinterval

No.

2 Lamp socket, Ø74x16, 1.4404 1049341 As neces‐sary

1

3 Lamp cover, Ø73x9, 1.4404 1049343 As neces‐sary

1

4 Retainer Ø48.5/39x3, PTFE 1035074 As neces‐sary

1


7 UV lamp 350 W, Vario-Flux® 1061418 14,000 hours 1

9 Locking screw, DIN 910, G 1/4A 1002752 As neces‐sary

1

11 O-ring/M, 10.50 - 1.50, EPDM/P 1001356 After eachopening

1

11 O-ring/M 18.00 - 2.00, EPDM/P 1002279 After eachopening

1


1

13 Socket, Ø25x1.9x15, PVDF 1075109 As neces‐sary

1

17 Wiper rod complete, UV-LP 1075593 As neces‐sary

1

19 Male socket, PG9 3+PE, Series 69 1017625 As neces‐sary

1

20 O-ring/M, 33.05 - 1.78, EPDM/P 1023570 As neces‐sary

1

22 UVC-U sensor, NDLP G1”, 1.4404 1075544 As neces‐sary

1

23 . Temperature sensor, PT1000, G1/4" 1059076 As neces‐sary

1

30 Lamp cover with plug, UV-LP, 230+ 1075127 As neces‐sary

1

33 Sensor connection cable, UV-LP, 13 m 1062315 As neces‐sary

1

33 Sensor connection cable, UV-LP, 4.5 m 1062303 As neces‐sary

1

33 Sensor connection cable, UV-LP, 9 m 1062314 As neces‐sary

1

34 PT1000 connection cable, UV-LP, 13 m 1075611 As neces‐sary

1

35 Lamp cable with cable socket, 12.5 m 1062319 As neces‐sary

1

35 Lamp cable with cable socket, 4 m 1062317 As neces‐sary

1

35 Lamp cable with cable socket, 8.5 m 1062318 As neces‐sary

1

Appendix

94


Replacementinterval

No.

40 Chamber cover complete, UV-LP, 1x350 1075596 As neces‐sary

1

41 Wiper rod complete, UV-LP 1075643 As neces‐sary

1

44 Clamping screw for wiper rod 1027928 As neces‐sary

1

48 O-ring 11.91 - 2.62, EPDM 790410 After eachopening

1

49 Bearing flange complete, for wiper rod 1027944 As neces‐sary

1

50 Socket, Ø16x1.8x15, PVDF 1027926 As neces‐sary

1


1

55 Clamping screw complete, for wiper rod 1027975 As neces‐sary

1

56 Fixing bushing with pins for UVR 1027930 As neces‐sary

1

57 Rotating mushroom knob GN 597.1-45 1027877 As neces‐sary

1

58 Guide bolt for UVR, M8/M10x65 1027931 As neces‐sary

1

60 Slotted pin, DIN 1473, 10x50 1028016 As neces‐sary

1

66 Wiper element for UVR/S/A 1027879 As neces‐sary

1

67 Spacer ring for UVR, Ø9.5x10.5 1027933 As neces‐sary

1

68 Support ring for UVR/S/A, Ø62/45x4, 1028100 As neces‐sary

1

70 Slide bearing 12x14/20x15, Iglidu® 1027848 As neces‐sary

1

83 Bearing ring, Ø50x10, PTFE 1049345 As neces‐sary

1

Appendix

95

12.3 Spare parts, 2 ... 4x350 W, multiple lamp system with wiper12.3.1 Spare part diagram, 2 ... 4x350 W, multiple lamp system with wiper

4

12517

278

10

22

20

1198281732

20

23

19

911

282311

A2479

A

A

Fig. 61: Spare part diagram, 2 ... 4x350 W, multiple lamp system with wiper

Appendix

96

A2246

42

41

5554

575150494844

43

45

17

46

5958

5653

40

52604147

7166

68

70

65

69

677273

B

B


Appendix

97

47

859085

85

49

91

66857050

48716981

8684

83

808182

A2247


Appendix

98

12.3.2 Spare parts list, 2x350 W, two lamp system with wiperSpare parts list, 2x350 W, two lamp system with wiper


Replacementinterval

No.




005 Lamp protection tube with seal, Ø4 1049344 3 years 1

007 UV lamp, 350W 1061418 14,000 hours 1

008 Magnetic sensor, MC60-12GM50 1009357 As necessary 1


010 Assembly bar, Æ18x250 1.4404 1041209 As necessary 1


1


1

017 Wiper rod complete, UV-LP 1051753 As necessary 1



1

022 UV sensor G 1. 1062329 As necessary 1

023 Temperature sensor, PT1000 G1/4" 1059076 As necessary 1

027 Angled cable socket, M12x1 3x0.34 mm2 1009479 As necessary 1



031 Connection socket with strands 1075083 As necessary 1


040 Reactor cover complete, UV-LP complete, 2x M 1051832 As necessary 1

041 Wiper unit complete, UV-LP 2x 1051849 As necessary 1

042 Drive thread, Tr20 x 4 x 1393, 1051768 As necessary 1

043 Hexagon nut, DIN 439 M10 1017585 As necessary 1

044 Shaft, Æ14 x 70 M10 1.4404 1049433 As necessary 1

045 Spacer bar, Æ12 x 1423.5 1.440 1051767 As necessary 1

046 O-ring/M 7.30 - 2.40, FPM-B 1059319 After eachopening

1

048 X-ring, 13.75x5.3x4.75 70, EPDM 28 1010384 After eachopening

1

049 Bearing cover complete, UVS/A 1037028 As necessary 1

050 Slip washer Æ15x1, IGLIDUR® H 1041199 As necessary 1

051 Bearing cover complete, UVR/A 1041183 As necessary 1

Appendix

99


Replacementinterval

No.


1

053 Distance pin, Æ10x82 M6 I/A 1041833 As necessary 1

054 Feather key, DIN 6885, A 2x 2x 14 1042863 As necessary 1

055 Coupling, TX1/10/C/8/8 1041484 As necessary 1

056 Flange plate, gear, UVA 1.44 1041830 As necessary 1

057 Tube, transparent, 50 x 3.7 792778 As necessary 1

058 EC motor, BG 44x50SI 24V DC 1041452 As necessary 1

059 Angled cable socket, M16 12-pin, 10 m 1041453 As necessary 1

060 Slotted pin, DIN 1473, 10x50 1028016 As necessary 1

065 Guide washer complete, UV-LP, 2x 1051851 As necessary 1

066 Wiper element for UVR/S/A 1027879 As necessary 1

067 Spacer ring, Æ9.5x10.5 for UVR1.4 1027933 As necessary 1

068 Holder ring, Æ62/45x4 for UVR/S/A PTF 1028100 As necessary 1

069 Threaded nut, Æ40x60 TR20x4 P 1049428 As necessary 1

070 Slide bearing, 12x14/20x15, IGLIDUR® 1027848 As necessary 1

071 Splint, DIN 94, 4x40 A4 1049429 As necessary 1

072 Retaining bolt for magnet, Æ20 1041793 As necessary 1

073 Magnetic bar, Æ8x40, PTFE 1049430 As necessary 1

080 Baffle plate with threaded rod, complete, UV-LP 1051869 As necessary 1

081 Counter-bearing spindle, Æ50x35 PV 1051868 As necessary 1

082 Tapping screw, DIN 7976, ST 4.8x1 1028585 As necessary 1


084 Slide bolt, Æ15x12, PTFE 1049426 As necessary 1

085 Slide bearing F 8x10x10, IGLIDUR® 1037033 As necessary 1

086 Hexagon nut, DIN 439, M 6 467006 As necessary 1

090 Assembly tool for bearing bush, UVS 1036907 As necessary 1

091 Spare parts kit, UVU, 2-lamp, MW 1059074 After 1000wiper cycles

1

Appendix

100

12.3.3 Spare parts list, 3x350 W, three lamp system with wiperSpare parts list, 3x350 W, three lamp system with wiper


Replacementinterval

No.

002 Lamp socket,Æ74x16 1.4404 1049341 As necessary 1


004 Retainer, Æ48,5/39x3 PTFE 1035074 As necessary 1


007 UV lamp, 350W 1061418 14,000 hours 1





1


1




1



027 Angled cable socket, M12x1, 3x0.34 mm2 1009479 As necessary 1




032 Locking screw, DIN 910, G 1A 1005766 As necessary 1

040 Reactor cover complete, UV-LP, 3x 1049421 As necessary 1



043 Hexagon nut, DIN 439, M10 1017585 As necessary 1




1


1




Appendix

101


Replacementinterval

No.


1

053 Distance pin Æ10x82, M6 I/A 1041833 As necessary 1



056 Flange plate gear, UVA 1.44 1041830 As necessary 1

057 Tube, 50 x 3.7, transparent 792778 As necessary 1




065 Guide washer UV-LP compl. 3x 1049402 As necessary 1




069 Threaded nut, Æ40x60, TR20x4 P 1049428 As necessary 1



072 Retaining bolt, Æ20 for magnet 1041793 As necessary 1



081 Counter-bearing spindle, Æ50x35, PV 1051868 As necessary 1








1

Appendix

102

12.3.4 Spare parts list, 4x350 W, four lamp system with wiperSpare parts list, 4x350 W, four lamp system with wiper


Replacementinterval

No.

002 Lamp socket,Æ74x16 1.4404 1049341 As necessary 1


004 Retainer, Æ48,5/39x3 PTFE 1035074 As necessary 1


007 UV lamp, 350W 1061418 14,000 hours 1





1


1




1



027 Angled cable socket, M12x1, 3x0.34 mm2 1009479 As necessary 1




032 Locking screw, DIN 910, G 1A 1005766 As necessary 1

040 Reactor cover complete, UV-LP, 4x 1074791 As necessary 1



043 Hexagon nut, DIN 439, M10 1017585 As necessary 1




1


1




Appendix

103


Replacementinterval

No.


1

053 Distance pin Æ10x82, M6 I/A 1041833 As necessary 1



056 Flange plate gear, UVA 1.44 1041830 As necessary 1

057 Tube, 50 x 3.7, transparent 792778 As necessary 1




065 Guide washer UV-LP compl. 4x 1074815 As necessary 1




069 Threaded nut, Æ40x60, TR20x4 P 1049428 As necessary 1



072 Retaining bolt, Æ20 for magnet 1041793 As necessary 1



081 Counter-bearing spindle, Æ50x35, PV 1051868 As necessary 1








1

Appendix

104

12.4 Dulcodes UV system operating logDate Turn-ons

UV lampOperatinghoursUV lamp

Signal dis‐playsensor[ %] //[w/m2] //[J/m2]

UVtrans‐mission[%/1cm]

Flow

[m3/h]Maintenance work per‐formed

Signature

Appendix

105

13 Declaration of ConformityIn accordance with DIRECTIVE 2006/42/EC OF THE EUROPEANPARLIAMENT AND OF THE COUNCIL, Appendix I, BASICHEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C.We,n ProMinent GmbHn Im Schuhmachergewann 5 - 11n D - 69123 Heidelberg, Germany,hereby declare that the product specified in the following, complieswith the relevant basic health and safety requirements of the EUDirective, on the basis of its functional concept and design and inthe version distributed by us. Any modification to the product notapproved by use will invalidate this declaration.

Extract from the EU Declaration of Conformity for Devices with Motor Wipers

Designation of the product: Dulcodes UV disinfection system

Product type: UVCb - - - - - - - - X - - - - - - - -X = 4, 5

Serial number: See nameplate on the device

Relevant EU directives: EU Machinery Directive (2006/42/EC)EU-EMC Directive (2014/30/EU)EU Pressure Equipment Directive (204/68/EUCompliance with the protection targets of the Low Voltage Directive2014/35/EU according to Appendix I, No. 1.5.1 of the Machinery Direc‐tive 2006/42/ECEU RoHS Directive (2011/65/EU)

Harmonised standards applied,in particular:

EN 12100:2010EN 60204-1:2009EN 60335-1:2014EN 60529:2014EN 61000-3-2:2015EN 61000-6-2:2006EN 61000-6-3:2012 (UVCbXXX…, XXX ≠ 04O-06O,)N 61000-6-4:2011 (UVCbXXX…, XXX = 04O-06O)

Applied national standards andother technical specifications inparticular:

AD 2000

Date: Heidelberg, 20.04.2016

The EC Declaration of Conformity is available to download on ourhomepage.

Declaration of Conformity

106

Extract from the EU Declaration of Conformity for Devices with Motor Wipers

Designation of the product: Dulcodes UV disinfection system

Product type: UVCbX ≠ 4, 5

Serial number: see nameplate on the device

Relevant EU directives: EU Low Voltage Directive (2014/35/EU)EU-EMC Directive (2014/30/EU)EU Pressure Equipment Directive (204/68/EUEU RoHS Directive (2011/65/EU)

Harmonised standards applied,in particular:

EN 12100:2010EN 60204-1:2009EN 60335-1:2014EN 60529:2014EN 61000-3-2:2015EN 61000-6-2:2006EN 61000-6-3:2012 (UVCbXXX…, XXX ≠ 04O-06O)EN 61000-6-4:2011 (UVCbXXX…, XXX = 04O-06O)

Applied national standards andother technical specifications inparticular:

AD 2000

Date: Heidelberg, 20.04.2016

The EC Declaration of Conformity is available to download on ourhomepage.

Declaration of Conformity

107

14 IndexAAction, step by step . . . . . . . . . . . . . . . . . . . . . . . . 2Applied harmonised standards . . . . . . . . . . . . . 106

CCAN-Bus status LED, internal . . . . . . . . . . . . . . . 14CANbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Control elements . . . . . . . . . . . . . . . . . . . . . . . . . 14

DData backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Declaration of Conformity . . . . . . . . . . . . . . . . . 106Degree of protection: IP 66 . . . . . . . . . . . . . . . . . 81Designation of the product . . . . . . . . . . . . . . . . 106Disinfection support . . . . . . . . . . . . . . . . . . . . . . . . 6

EEmergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10EU Declaration of Conformity . . . . . . . . . . . . . . 106

FFingerprints on the UV lamp . . . . . . . . . . . . . . . . 53

GGeneral non-discriminatory approach . . . . . . . . . . 2

IInstructions: Replacing the wearing parts . . . . . . 52IP 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

KKeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

LLamp switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . 13LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Links to elements or sections of these instruc‐tions or other applicable documents . . . . . . . . . . . 2

MMaintenance work: Dismantling . . . . . . . . . . . . . . 54Maximum temperature . . . . . . . . . . . . . . . . . . . . 13More symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

NNon-discriminatory approach . . . . . . . . . . . . . . . . 2

OOperating error . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Operating indicator . . . . . . . . . . . . . . . . . . . . . . . 14Operating parameter . . . . . . . . . . . . . . . . . . . . . . 10Operating temperature . . . . . . . . . . . . . . . . . . . . 12Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PPermissible ambient conditions during operation 11Permissible ambient conditions during storage . 11PROFIBUS® . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

QQuestion: What is the typical installation layoutof a UV system? . . . . . . . . . . . . . . . . . . . . . . . . . 12Question: Which wearing parts do I have toreplace? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

RRecycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Relevant EC directives . . . . . . . . . . . . . . . . . . . 106

SSD cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . 106Service life of the SD card . . . . . . . . . . . . . . . . . . 16Spare parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Start rinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

UUltraviolet radiation . . . . . . . . . . . . . . . . . . . . . . . 10Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Users' qualifications . . . . . . . . . . . . . . . . . . . . . . . 8UV output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13UV transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 9

WWarm-up time . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Warning indicator . . . . . . . . . . . . . . . . . . . . . . . . 14Warning information . . . . . . . . . . . . . . . . . . . . . . . 7Water temperature . . . . . . . . . . . . . . . . . . . . . . . 13Where do I find the performance data? . . . . . . . . . 6

Index

108

109

110

111

983668, 2, en_GB

© 2017

ProMinent GmbHIm Schuhmachergewann 5 - 1169123 Heidelberg, GermanyTelephone: +49 6221 842-0Fax: +49 6221 842-419Email: [email protected]: www.prominent.com

Dulcodes LP with Comfort Controller, UV systemprominent.us/promx/pdf/983668_BA_DS_055_07_17_EN_LP_UV.pdf · Dulcodes LP with Comfort Controller UV system ... 7 Commissioning ... the

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